Faja Overland o&m Manual 620mr002-Preliminary

620MR00
02‐A

Thysse
T enKrup
pp Robins, Inc.

MECH
HANIC
CAL
OPE
ERATION AND MAINT
M NCE M
ENAN MANUA
AL
TKRII PRO
OJECT
T # 10
002
2011
2

AN
NTAPAC
CCAY PROJE
P ECT - TINTAYA
A EXPA
ANSION
N
CO
ONVEY
YING SY
YSTEM
TABLE OF CONTENTS
1 GENERAL INFORMATION
1.1 TKRI SAFETY CREED 5

1.2 TKRI SAFETY STANDARD FOR CONVEYORS 8
1.3 CONTROL NARRATIVE 35
2 PROJECT DATA
2.1 CONVEYOR DATA SHEET 96

2.2 DRAWING LIST 97
2.3 GENERAL ARRANGEMENT'S 116
2.4 P&ID'S 135
2.5 MECHANICAL EQUIPMENT LIST 145
3 MAINTENANCE
3.1 OPERATING & MAINTENANCE MANUAL 150

3.2 SPARE PARTS 182
3.3 LUBRICATION REQUREMENTS 183
4 EQUIPMENT MANUALS
4.1 METAL DETECTOR SERIES 9000A, ADVANCED DETECTION SYSTEMS 189

4.2 HOOD COVERS, CAPOTEX 215
4.3 IDLERS, LORBRAND 226
4.4 BELT SCALE, MERRICK 270
4.5 TAKE-UP WINCH, P&H MINEPRO 477
4.6 CONVEYOR BELTS, PHOENIX 625
4.7 BELT RIP DETECTION SYSTEM, PHOENIX 681
4.8 CONVEYOR PULLEYS, RAS 742
4.9 BELT CLEANERS, RICHWOOD 813
4.10 DRIVE MOTOR SACRIFICIAL CONVEYOR, SIEMENS 862
4.11 GEARLESS MOTOR, SIEMENS 863
4.12 REDUCER PARAMAX 9000, SUMITOMO 1131
4.13 MOTORIZED BELT REEL, SUMITOMO 1338
4.14 CONVEYOR BRAKES, SVENDBORG 1431
4.15 WINCH HEAD PULLEY REMOVAL, THERN 1609
4.16 HOIST HEAD PULLEY REMOVAL, YALE 1647
Table of Contents
1GENERAL INFORMATION
1 GENERAL INFORMATION
1.1 TKRI SAFETY CREED 5

1.2 TKRI SAFETY STANDARD FOR CONVEYORS 8
1.3 CONTROL NARRATIVE 35
Table of Contents 1 General Info.
ThyssenKrupp Safety Creed

1. START UP
1.1 Maintenance
All equipment shall be assembled in accordance with the instructions,
specifications, drawings and recommendations of the manufacturer. No
modifications, adjustments or alterations shall be made to the equipment
without prior approval.
Equipment shall be thoroughly cleaned prior to assembly. All alignments on
equipment either pre-assembled or field assembled shall be checked and
adjusted where necessary after shimming and setting.
Installation of rotating equipment shall be in accordance with the following:
After installation, each piece of rotating equipment shall be checked by
hand to ensure that the rotating parts are free of interference.
During installation, bearing end floats shall be checked.
Final assembly of couplings or V belt drives on non-reversible equipment
shall not be completed until the proper direction of motor rotation is
confirmed.
Safety guards shall be installed around all exposed moving parts.
1.2 Start-up
Prior to the energizing of any equipment, all safety devices including brakes (if
applicable) must be functioning properly and all switches shall be in their proper
positions.
The following instructions are imperative and shall be the responsibility of
operations personnel:
All technical and operational safety rules and regulations shall be
complied with.
All operating personnel shall be aware of the location of all emergency
shutdown switches, and of all local control switches.
The system shall have been inspected, and extraneous objects,
materials etc. shall have been removed.
All local control station mode operation control switches shall have been
set to the proper positions.
The system shall initially be operated without load to confirm proper
functioning of components.
No materials or capacities deviating from those specified shall be
handled.

Operations personnel shall continuously monitor all systems for unusual
operating characteristics (strange noises, smells etc.), and shall
immediately investigate any such disparities. Any necessary shutdown,
repair and/or adjustment of the system shall immediately be
implemented.
All site safety practices shall be observed.
1.3 After Extended Shutdowns
Following an extended shutdown period the system shall be thoroughly cleaned
and inspected and appropriate repairs and be replacements shall be made. The
inspection shall include, but not necessarily be limited to the following:
Parts subjected to wear.
Idlers.
Conveyor belting.
Brakes.
Flexible and fluid couplings.
Belt scrapers.
Chutes and skirtboards.
Electrical equipment.
Lubrication points.
Depending on the length of the preceding shutdown, the quality of existing
lubricants in gearboxes, hydraulic systems, pillow blocks, slew bearings etc.
shall be checked, and lubricants shall be flushed if necessary.
Following these preliminary inspections, start-up procedures shall correspond
to those outlined above.
1.4 Check Lists
Prior to start-up of any equipment, the following checks shall be performed and
appropriate repairs and/or replacements shall be made:
Pulleys
wear, damage or glazing on lagging
pillow blocks greased and correctly aligned
Gear Reducers
oil levels correct

casings damaged or leaking
Couplings
correct hydraulic fluid levels
correct alignment
Brakes
correct brake thruster oil levels
excessive wear of brake linings
correct alignment
Belt Scrapers
correct tension
blade wear
excessive build-up of material on blades or frames
Conveyor
all idlers present and in proper operating condition
correct belt alignment
excessive belt wear
side travel switches operating smoothly
pull cord switches operating smoothly; pull cords in good condition
excessive build-up of material in chutes
ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT
SAFETY STANDARD FOR

CONVEYORS AND RELATED EQUIPMENT
INTRODUCTION
Accidents resulting from the manual handling of materials have been reduced by the use of
conveying and other forms of mechanical handling equipment. A further reduction in the accident rate
can be gained by following safe practices in the design, construction, installation, operation, and
maintenance of such equipment.
The design and installation of conveyors and conveyor systems should be supervised by qualified
engineers. Likewise, the operation and maintenance of conveyors and systems should be supervised
by trained personnel.
The purpose of this Standard is to present certain guides for the design, construction, installation,
operation, and maintenance of conveyors and related equipment.
Those portions of this Standard relating to maintenance and operation procedures are fully as
important as those relating to design and installation. The best design features may be negated by
faulty maintenance and operating practices. It is important that operating and maintenance personnel
be instructed in recognizing hazards and pertinent safety precautions.
1 SCOPE
This Standard applies to the design, construction, installation, maintenance, inspection, and
operation of conveyors and conveying systems in relation to hazards. The conveyors may be
of the bulk material, package, or unit handling types where the installation is designed for
permanent, temporary, or portable operation.
This Standard shall apply, with the exceptions noted below, to all conveyor installations.
This Standard specifically excludes any conveyor designed for, installed for, or used primarily
for the movement of human beings. This Standard does, however, apply to certain conveying
devices that incorporate within their supporting structure work stations or operator's stations
specifically designed for authorized operating personnel.
This Standard does not apply to conveyors such as underground mine conveyors for which
specific standards are already in effect, or to equipment such as industrial trucks, tractors,
trailers, automatic guided vehicles, tiering machines (except pallet load tierers), cranes, hoists,
power shovels, power scoops, bucket drag lines, trenchers, platform elevators designed to
carry passengers or an operator, man-lifts, moving walks, moving stairways (escalators),
highway or railroad vehicles, cableways, tramways, dumbwaiters, pneumatic conveyors,
robots, or integral machine transfer devices. Some of the foregoing have specific standards.
The provisions of this Standard shall apply to equipment installed one year after the date of
issuance.
Page 6 of 180
2 REFERENCE TO OTHER CODES
Certain other codes and standards have been cited as references in this Standard. Reference
to them does not constitute inclusion of the complete text of such codes or standards as a part
of this Standard.
This Safety Standard for conveyors is supplementary to any law or code covering fire or
health regulations.
3 INTENT
The intent of this Standard is to provide for safe operation and maintenance of conveying
equipment.
Suggestions for improvement of this Standard may be submitted to the Secretary of the B20
Committee, ASME, Three Park Avenue, New York, NY 10016-5990.
Proposals should be written in accordance with the following format:
(a) Specify page and paragraph designation of the pertinent Standard.

(b) Indicate suggested change (addition, deletion, revision, etc.).
(c) Briefly state reason and/or evidence for suggested change.
(d) Separately submit suggested changes if more than one paragraph is affected.
The B20 Committee will consider each suggested change at its first meeting after receipt of
the suggested change(s).
The B20 Committee will render an interpretation of any requirement of the Standard.
Interpretations will be rendered only in response to a written request sent to the Secretary of
the B20 Committee, ASME International, Three Park Avenue, New York, NY 10016-5990.
The request for interpretation shall be in the following format:
Subject: Cite the applicable paragraph number(s) and provide a concise description.
Edition: Cite the applicable edition of the standard for which the interpretation is being
requested.
Question: Phrase the question as a request for an interpretation of a specific requirement

suitable for general understanding and use, not as a request for an approval of a
proprietary design or situation. The inquirer may also include any plans or
drawings that are necessary to explain the question; however, they should not
contain proprietary names or information.
ASME procedures provide for reconsideration of any interpretation when or if additional

information that might affect an interpretation is available. Further, persons aggrieved by an
interpretation may appeal to the cognizant ASME committee. ASME does not "approve,"
"certify," "rate," or "endorse" any item, construction, proprietary device, or activity.
Page 7 of 180
4 DEFINITIONS1
actuator: a device that initiates the action of controls or controllers and is manually operated.
The actuator may be a push button, toggle switch, foot pedal, hand lever, hand-set
timer, or any other device that performs the described function.
Anti-runaway: a safety device to stop a declining conveyor and thus prevent moving away in
the event of a mechanical or electrical failure.
apron pan: one of a series of overlapping or interlocking plates or shapes that, together with
others, form the conveyor bed.
automatically controlled: describes the operation be the action of a mechanism that is

initiated by some impersonal influence, such as a conveyor that is started by a low
level bin indicator.
backstop: a mechanical device to prevent reversal of a loaded conveyor under action of

gravity when forward travel is interrupted.
bed
(a): that part of a conveyor upon which the load or carrying medium rests or slides
while being conveyed
(b): in bulk material conveyors, the mass of material being conveyed
belt idler: a roller or series of rollers that supports the belt of a belt conveyor.
belt tripper: a device incorporating a system of pulleys that causes the conveyor belt to
discharge material at one or more points along the length of the conveyor.
boom: a cantilevered member or structure that may be hinged, fixed, or pivoted.
brake: a friction device for slowing down conveyor components, bringing conveyor
equipment to a controlled stop, holding traveling or traversing equipment in a
selected location, preventing reverse travel, and controlling over-speed due to the
action of gravity.
bunker: a large bin or compartment for storage of bulk materials.
car unloader: a type of conveyor characterized by a shallow, horizontal loading section that
enables it to receive and unload material from hopper bottom cars without
requiring a pit or other excavation.
carrier:
(a): a device attached to or hung from trolleys to support the load
(b): the receptacle in which objects are placed for transmittal through a conveying
system
(c): the moving part of a vertical or inclined reciprocating conveyor that supports
the load
chain: a series of links pivotally joined together to form a medium for conveying or
transmitting motion or power. General classes of chain common to conveyors are
detachable, pintle, combination, roller, rivetless, coil, inverted tooth, and bar link
chains.
Page 8 of 180
1
Many definitions were extracted from the latest revision of Conveyor Terms and Definitions, Book No. 102, prepared by the
Engineering Conference of the Conveyor Equipment Manufacturers Association, Washington, DC 20850. For definitions of
terms other than those defined in Section 4, refer to this publication.
chute: a trough through which bulk materials or objects are directed and lowered by
gravity. The trough may be open or enclosed, straight of curved.
control: the system governing the starting, stopping, direction of motion, acceleration,
speed, retardation, identification, and function of the moving member in a
predetermined manner.
controller: an electromechanical device or assembly of devices for starting, stopping,

accelerating, or decelerating a drive, or serving to govern in some predetermined
manner the power delivered to the drive.
conveying medium: that portion of a conveyor that moves or carries materials, packages, or
objects.
conveyor: a horizontal, inclined, or vertical device for moving or transporting bulk material,
packages, or objects, in. a path predetermined by the design of the device, and
having points of loading and discharge, fixed or selective. Included are skip hoists
and vertical reciprocating and inclined reciprocating conveyors. Typical exceptions
are those devices known as industrial trucks, tractors, trailers, tiering machines
(except pallet load tierers), cranes, hoists, power shovels, power scoops, bucket
drag lines, trenchers, platform elevators designed to carry passengers or an
operator, man-lifts, moving walks, moving stairways (escalators), highway or
railway vehicles, cableways, tramways, dumbwaiters, pneumatic conveyors,
robots, or integral machine transfer devices.
conveyor belt: a belt used to carry materials and transmit the power required to move the load
being conveyed.
conveyor screw: the material propelling medium of a screw conveyor generally consisting of
an assembly of helical flights mounted on a rotating pipe or shaft.
conveyor, apron: a conveyor in which a series of apron pans forms a moving bed.
conveyor, belt: an endless fabric, rubber, plastic, leather, or metal belt operating over suitable
drive, tail end, and bend terminals and over belt idlers or slider bed for handling
bulk materials, packages, or objects placed directly upon the belt.
conveyor, bucket: any type of conveyor in which the material is carried in a series of buckets.
conveyor, chain: any type of conveyor in which one or more chains act as the conveying
medium; a British term for trolley conveyor.
conveyor, declining: a conveyor transporting down a slope.
conveyor, electrified monorail: a conveyor consisting of a network of tracks or guide rails that
may be installed horizontally, vertically, inclined, or in combination with one or
more self-propelled cars or trolleys that move independently under automatic
Page 9 of 180
control from one point to another within the track network, carrying material in
containers or by devices suspended from or attached to the cars or trolleys.
conveyor, en masse: a conveyor, comprised of a series of skeleton or solid flights on an

endless chain or other linkage, that operates in horizontal, inclined, or vertical
paths within a closely fitted casing for the carrying run. Bulk material is conveyed
and elevated in a substantially continuous stream with a full cross section of the
casing.
conveyor, extendable: a conveyor that may be lengthened or shortened to suit operating

needs.
conveyor, flight: a type of conveyor comprised of one or more endless propelling media, such
as chain, to which flights are attached, and a trough through which material is
pushed by the flights.
conveyor, horizontal reciprocating: a conveyor that progressively advances material by a

back-and-forth motion of its conveying medium. It may be equipped with hinged
flights or tilting dogs or pushers. These units operate generally in the range of 0
degrees to 30 degrees from the horizontal.
conveyor, inclined reciprocating. a reciprocating power or gravity actuated unit (not designed
to carry passengers or an operator) that receives objects on a carrier. These units
operate on inclines generally in the range of 30 degrees to 70 degrees from the
horizontal.
conveyor, live roller: a series of rollers over which objects are moved by the application of
power to all or some of the rollers. The power transmitting medium is usually
belting or chain.
conveyor, mobile: conveyor, supported on a structure, which is movable under its own power
and includes, but is not limited to, radial stackers, winged stackers, reclaiming
conveyors, and shiploaders. These conveyors normally handle bulk material.
conveyor, oscillating: a type of vibrating conveyor having a relatively low frequency and large
amplitude of motion, usually powered by a rotating eccentric.
conveyor, overland: a single or series of belt conveyors designed to carry bulk material
across country, usually following the general contour of the land.
conveyor, portable: a transportable conveyor that is not self-propelled, usually having

supports that provide mobility.
conveyor, power and free: a conveying system wherein the load is carried on a trolley or
trolleys that are mechanically propelled through part of the system and may be
gravity or manually propelled through another part. This arrangement provides a
means of switching the free trolleys into and out of adjacent lines. The spur or
subsidiary lines may or may not be powered.
conveyor, pusher bar: two endless chains cross-connected at intervals by bars or rotatable
pushers that propel the load along the bed or trough of the conveyor.
Page 10 of 180
conveyor, reciprocating: a conveyor where the carrier or pusher moves forward and back, or
up and down, in the same plane.
conveyor, roller: a series of rollers supported in a frame over which objects are advanced
manually, by gravity, or by power.
conveyor, roller slat: a slat conveyor using rollers for slats.
conveyor, screw: a conveyor screw revolving in a suitably shaped stationary trough or casing
fitted with hangers, trough ends, and other auxiliary accessories.
conveyor, shuttle: any conveyor such as a belt, chain, apron, screw, etc., in a self-contained
structure, movable in a defined path parallel to the flow of the material.
conveyor, slat: a conveyor employing one or more endless chains to which non-overlapping,
non-interlocking spaced slats are attached.
conveyor, suspended tray: a vertical conveyor, having one or more endless chains with
suitable pendant trays, cars, or carriers, that receives objects at one elevation and
delivers them to another elevation.
conveyor, tow: an endless belt or cable driven system, or (03) chain supported by trolleys
from an overhead track or running in a track with means for towing floor-supported
or rail-guided trucks, dollies, or carts.
conveyor, trolley: a series of trolleys supported from or within an overhead track and
connected by endless propelling means, such as chain, cable, or other linkage,
with loads usually suspended from the trolleys.
conveyor, vertical articulated: a type of vertical conveyor in which sections of articulated slat
conveyor apron form rigid carriers for vertical movement in continuous flow. The
carriers are flexible in but one direction, and they assume a vertical position on the
non-carrying run to minimize space requirements.
conveyor, vertical chain, opposed shelf type: two or more vertical elevating-conveying units
opposed to each other. Each unit consists of one or more endless chains whose
adjacent facing runs operate in parallel paths. Thus each pair of opposing shelves
or brackets receives objects (usually dish trays) and delivers them to any number
of stations.
conveyor, vertical reciprocating: a reciprocating power or gravity actuated unit (not designed
to carry passengers or an operator) that receives objects on a carrier and transmits
these objects vertically between two or more levels.
conveyor, vibrating: a trough, tube, or other device flexibly supported and vibrated at a
relatively high frequency and small amplitude to convey bulk material or objects;
usually powered by an electrical or pneumatic impulse.
conveyor, wheel: a series of wheels supported in a frame over which objects are moved
manually or by gravity.
Page 11 of 180
deflector
(a): a device across the path of a conveyor placed at an angle and designed to
deflect objects
(b): a plate inserted in the trajectory of a bulk material discharge to change
direction
drive: an assembly of the necessary structural, mechanical, and electrical parts that
provide the motive power for a conveyor.
drum: a cylindrical or polygonal rim type of wheel around which cable, chain, belt, or
other linkage may be wrapped. A drum may be drive or driving. The face may be
smooth, grooved, fluted, or flanged.
dumbwaiter: a type of material lifting device specifically limited to a platform area of 0.8 m (9
ft2) or less, and inside car height of 1.2 m (4 ft) or less, and a hoistway door height
of 1.24 m (4 ft 1 in.) or less. 2
emergency stop: a stop arising from a sudden and unexpected need, and not as a part of the
normal operation.
emergency stop device: a device that can be actuated in an emergency situation to stop a
conveyor.
enclosed: describes guarding of moving parts in such a manner that inadvertent physical
contact by parts of the body is precluded as long as the guard or enclosure
remains in place. The guarding may make use of hinged, sliding, or removable
doors for inspection or service.
flight
(a): plain or shaped plates suitably made for attachment to the propelling medium
of a flight conveyor.
(b): a term applied to any section of a conveyor in a tandem series.
gate: a device or structure by means of which the flow of material may be stopped or
regulated; also, a section of conveyor equipped with a hinge mechanism for mov-
able service, often called a hinged section.
grating
(a): a coarse screen made of parallel or crossed bars to prevent passage of
oversize material
(b): a series of parallel and crossed bars used as platform or walkway floors, or as
coverings for pits and trenches over which traffic may pass. Generally remov-
able to permit access to conveying equipment for servicing
(c): a series of parallel or cross bar units, or both, fastened to or propelled by the
conveying medium, used for carrying large lump-sized bulk material or objects.
Generally used to permit passage of air for cooling or heat to maintain
temperature
guard
(a): a covering, barricade, grating, fence, or other form of barrier used to prevent
inadvertent physical contact with operating components such as gears,
sprockets, chains, and belts
Page 12 of 180
(b): a structure mounted below an overhead mounted conveyor to protect

personnel from falling materials
guarded: shielded, fenced, enclosed, or otherwise protected by means of suitable enclosure,

covers, casing, shields, troughs, railings, or by nature of location so as to reduce
risk of personal injury.
guarded by location: describes moving parts so protected by their remoteness from the floor,
platform, walkway, or other working level, or by their location with reference to
frame, foundation, or structure as to reduce risk of accidental contact by persons
or objects. Remoteness from regular or frequent presence of public or employed
personnel may, in reasonable circumstances, constitute guarding by location.
hopper: a box having a funnel-shaped bottom, or a bottom reduced in size, narrowed, or

necked to receive material and direct it to a conveyor, feeder, or chute.
2
See ASME A17.1 for dumbwaiter safety requirements.
inactive controls: those controls that are not a part of, or do not contribute to, the present or
future contemplated use of the conveyor or system as presently installed and
wired.
integral machine transfer device: a part of a machine that loads, unloads, or transfers
material (parts) from one location to another within the machine, during processing
of the material, and without which the machine could not perform its function.
Typically, both the machine and transfer device are supplied together and share
the power and control systems.
limit switch: an electrical device by which the movement of a conveyor and allied equipment
may be controlled within predetermined limits.
nip point: a point at which a machine element moving in line meets a rotating element in
such a manner that it is possible to nip, pinch, squeeze, or entrap a person or
objects coming into contact with one of the two members. The same definition
holds for the similar point with respect to two rotating parts or two converging parts
in linear movement.
operator's station: location at which actuators are placed for the purpose of starting, stopping,
reversing, or otherwise controlling the conveyor or system of conveyors in the
course of normal operation.
overload device: a mechanical or electrical device designed to disconnect the driven

equipment from the driving equipment in event of an overload on the conveyor.
platform: a working space for persons, elevated above the surrounding floor or ground (such
as a balcony) for the operation of machinery and equipment.
prevent: when used in a context such as prevent access or prevent physical contact, means
to impede or block; when used in the context such as prevent injury, means to
reduce the chances of, but does not imply that an injury cannot occur.
Page 13 of 180
qualified person: a person who, by possession of a recognized degree or certificate of

professional standing, or who, by extensive knowledge, training, and experience,
has successfully demonstrated his/her ability to solve problems relating to the
subject matter and work.
rail
(a): one of the longitudinal members in a conveyor frame
(b): the supporting surface under the wheels or rollers of a chain conveyor
(c): the supporting track for equipment mounted on wheels, such as belt tripper,
weigh larry etc
(d): the vertical members that guide the pendant trays, cars, or carriers in a
suspended vertical tray conveyor
rail clamp: an attachment or device for clamping a mobile conveyor or belt tripper to the rail to
hold it in a fixed location.
rail stop: a stop mounted on the conveyor rails to limit the travel of traversing machinery.
railing guard (guardrail): a structure consisting of rails and posts, including top rail, post, and,
where required, toe-boards.
rated capacity: the capacity at the rated speed, as established by the manufacturer or a
qualified person, at which safe and satisfactory service can be expected.
rated speed: the speed of the conveyor, as established by the manufacturer or a qualified
person, at which safe and satisfactory service can be expected.
remote control: any system of controls in which the actuator is situated in a remote location.
remote location: any location, with respect to the conveyor, from which the presence or
position of personnel relative to the conveyor cannot be readily determined from
the operator's station.
roller
(a): a revolving cylinder or wheel over which something is moved. The face may
be straight, tapered, crowned, concave, or flanged; corrugated, ribbed, or
fluted
(b): a component part or a roller chain in which it may serve only to reduce
frictional loss occurring as the chain passes over the sprockets. Rollers may
also serve as the rolling support for the chain and the load being conveyed
(c): the rotating element upon which a conveyor belt or chain or the object being
transported is carried
roller turn: a series of vertical rollers mounted in a frame to guide conveyor chain around a
horizontal curve.
safety device: a mechanism or an arrangement placed in use for the specific purposes of
preventing an unsafe condition, preventing the continuation of an unsafe condition,
warning of an unsafe condition, or limiting or eliminating the unsafe effects of a
possible condition.
Page 14 of 180
shall: as used in the context of a provision of this Standard, indicated that the provision is
mandatory and must be followed.
shear point or line: the point at which, or the line along which, a moving part meets or passes
close enough to a stationary or moving part or object so that part of the human
body can be caught, trapped, or pinched between them.
shield guard: a full or partial enclosure or cover, either framed or solid, made from material
sufficiently rigid to prevent accidental contact with moving parts.
should: as used in the context of a provision of this Standard, indicates a recommendation,

the advisability of which depends on the facts in a particular situation.
skip bucket: the tub or bucket used for containing the material conveyed by a skip hoist.
skip hoist: a bucket or car operating up and down a defined path receiving, elevating, and
discharging bulk materials.
slat: a member supported between chains in a slat conveyor; the series of slats form
the conveying medium.
snub roller: any pulley used to increase the arc contact between a belt and drive or trail
pulley.
spill guard: a stationary device of sufficient strength and capacity to catch, retain, and
contain any reasonably foreseeable spillage from a conveyor passing overhead
that might cause personal injury.
stacker. a conveyor adapted to piling or stacking bulk materials, packages, or objects.
switch
(a): a device for connecting two or more continuous package conveyor lines
(b): an electrical control device
(c): a mechanism that transfers a trolley, carrier, or truck from one track to
another at a converging or diverging section
switch, slack cable: a device installed to automatically shut off the power supply when the
hoisting cable becomes slack or has slack due to accident or jamming.
take-up: the assembly of the necessary structural and mechanical parts that provides the
means to adjust the length of belts, cables, chains, etc., to compensate for
stretch, shrinkage, or wear, and to maintain proper tension.
terminal: a term normally applied to the extreme ends of a belt system, i.e., head and tail
pulleys.
tow pin: a moveable or fixed member on a truck, dolly, or cart used to engage the power
system on a tow conveyor.
tracks: the beams, shapes, or formed section on which trolleys, rollers, shoes, or
wheels roll or slide while being propelled.
Page 15 of 180
transfer can any wheeled device used for transferring loads from one conveyor line to
another; may be manually or automatically operated.
transfer mechanism: any mechanism that transfers objects onto or off a conveyor line or
from one conveyor line to another.
tray: a car, carrier, or pallet, usually suspended from the moving element of the
conveyor, used to carry conveyed loads.
tread plate: a plate of suitable size fitted between conveyor rollers to permit persons to use
it as a working or walking surface.
trolley: an assembly of wheels, bearings, and brackets used for supporting and moving
suspended loads or for carrying load connecting and conveying elements such
as chain, cable, or other linkage.
truck (also known as cart)

(a): an assembly that supports another unit in either a fixed or adjustable position
and that provides mobility
(b): a wheeled vehicle that can be detached from a conveying medium (usually
chain) and pushed by hand
walkway: an elevated passageway for persons above the surrounding floor or ground
level, including catwalks, foot-walks, runways, and elevated walkways.
work station: a physical location where a person is normally positioned, which is located by
design and supported with facilities necessary for a person to perform prescribed
work duties. This position would not apply to maintenance location.
5 GENERAL SAFETY STANDARDS3
5.1 Application
Conveyor equipment shall be used to convey only the specified commodities or

materials within the rated capacity and the rated speed. Where special use is not
indicated, or ratings are not available, good industry practice shall be used.
5.2 Maintenance (Repair)
(a) Maintenance and service shall be performed by qualified and trained

personnel.
(b) Where lack of maintenance and service would cause a hazardous condition,
the user shall establish a maintenance program to ensure that conveyor
components are maintained in a condition that does not constitute a hazard
to personnel.
(c) No maintenance or service shall be performed when a conveyor is in

operation except as provided in paragraphs. 5.3 and 5.4.
Page 16 of 180
(d) When a conveyor is stopped for maintenance or service, the starting devices,
prime movers, or powered accessories shall be locked or tagged out in
accordance with a formalized procedure designed to protect all persons or
groups involved with the conveyor against an unexpected restart. Personnel
should be alerted to the hazard of stored energy, with may exist after the
power source is locked out. Refer to ANSI Z244.1-1982, American National
Standard for Personnel Protection - Lockout/Tagout of Energy Sources -
Minimum Safety Requirements, and OSHA Standard 29 CFR 1910.147, "The
Control of Hazardous Energy (Lockout/Tagout)."
(e) All safety devices and guards shall be replaced before starting equipment for
normal operation.
5.3 Lubrication
(a) Conveyors shall not be lubricated while in operation unless it is impractical to

shut them down for lubrication. Only trained and qualified personnel who are
aware of the hazards of the conveyor in motion shall be allowed to lubricate a
conveyor that is operating.
(b) Where the drip of lubricants or process liquids on the floor constitutes a
hazard, drip pans or other means of eliminating the hazard shall be provided.
5.4 Adjustment or Maintenance During Operation
When adjustment or maintenance must be done while equipment is in operation, only

trained and qualified personnel who are aware of the hazard of the conveyor in motion
shall be allowed to make adjustment or perform the maintenance or service.
3
IMPORTANT: The general safety standards in Section 5 form a part of, and must be used with, the specific standards in Section 6.
5.5 Backstops and Breaks
Anti-runaway, brake, or backstop devices shall be provided on all incline, decline, or

vertical conveyors, where the effect of gravity will allow uncontrolled lowering of the
load and where this load will cause a hazard to personnel.
5.6 Overload Protection
Where overload conditions would cause damage to equipment that could result in a
personal injury, overload devices or suitable warning means shall be provided.
5.7 Gates and Switches
(a) Power positioned gate and switch sections shall be provided with devices that
will prevent these sections from falling in case of power failure.
(b) Means shall be provided on all gate and switch sections to prevent conveyed
material from discharging into the open area, created by lifting of the gate or
switch.
Page 17 of 180
5.8 Counterweights
When counterweights are supported by belts, cables, chains, and similar means,
weights shall be confined in an enclosure to prevent the presence of personnel
beneath the counterweight. As an alternative the arrangement shall provide a means
to restrain the falling weight in case of failure of the normal counterweight support.
5.9 Guards and Guarding
5.9.1 General Requirements of Guarding
5.9.1.1 Guarding.
Where necessary for the protection of personnel from hazards, all
exposed moving machinery parts that present a hazard to personnel at
work stations or operator's stations shall be mechanically or electrically
guarded, or guarded by location or position.
5.9.1.2 Interfacing of Equipment. When two or more pieces of equipment

are interfaced, special attention shall be given to the interfaced area to
ensure the presence of adequate guarding and safety devices.
5.9.1.3 Guarding Exceptions. Wherever conditions prevail that would require

guarding under this Standard
but such guarding would render to conveyor unusable, prominent
warning means, such as signs or warning lights, shall be provided in
the area or on the equipment in lieu of guarding.
5.9.1.4 Maintenance of Guards and Safety Devices. Guards and safety

devices shall be maintained in a serviceable and operational condition.
Warning signs provided in accordance with para. 5.9.1.3 shall be
maintained in a legible/operational condition.
5.9.2 Guarding by Location or Position

(a) Remoteness from frequent presence of public or employed personnel shall
constitute guarding by location.
(b) Overhead conveyors, such as trolley conveyors and hanger-suspended
tray conveyors, for which guarding would render the conveyor unusable or
would be impracticable, shall have prominent and legible warnings posted in
the area or on the equipment and, where feasible, lines shall be painted on the
floor delineating the danger area.
(c) When a conveyor passes over a walkway, roadway, or work station, it is
considered guarded by location if all moving parts are at least 2.44 m (8 ft)
above the floor or walking surface or are otherwise located so that personnel
cannot inadvertently come in contact with hazardous moving parts.
(d) Although overhead conveyors may be guarded by location, spill guards,
pan guards, or equivalent shall be provided if material may fall off the conveyor
and endanger personnel.
5.9.3 Guarding of Nip and Shear Points. In general, nip and shear points shall be
guarded unless other means to ensure safety are provided. See Section 6 for
specific conveyors.
Page 18 of 180
5.10 Headroom
(a) When conveyors are installed above exit passageways, aisles, or corridors, there
shall be provided a minimum clearance of 2.00 m (6 ft 8 in.) measured vertically from
the floor or walking surface to the lowest part of the conveyor or guards.
(b) Where system function will be impaired by providing the minimum clearance of
2.00 m (6 ft 8 in.) through an emergency exit, alternate passageways shall be
provided.
(c) It is permissible to allow passage under conveyors with less than 2.00 m (6 ft 8 in.)
clearance from the floor for other than emergency exits if a suitable warning indicates
low headroom.
5.11 Controls
5.11.1 Electrical Code. All electrical installations and wiring shall conform to the
National Electrical Code (Article 670 and other applicable articles) as published
by the National Fire Protection Association and as approved by the American
National Standards Institute, Inc.
5.11.2 Control Station

(a) Control stations should be so arranged and located that the operation of the
affected equipment is visible from them. Control stations shall be clearly
marked or labeled to indicate the function controlled.
(b) A conveyor that would cause injury when started shall not be started until
personnel in the area are alerted by a signal or by a designated person that the
conveyor is about to start.
(1) When a conveyor that would cause injury when started is automatically
controlled or must be controlled from a remote location, an audible
device or devices shall be provided that can be clearly heard at all
hazardous points along the conveyor where personnel may be present.
The audible warning shall be actuated by the controller device starting
the conveyor and shall continue for a required period of time before the
conveyor starts. A flashing light or similar visual warning may be used
in conjunction with, or in place of, the audible device if a visual warning
is more effective.
(2) Where system function would be seriously hindered or adversely
affected by the required time delay, or where the intent of the warning
may be misinterpreted (i.e., a work area with many different conveyors
and allied devices), a clear, concise, and legible warning sign shall be
provided. The warning sign shall indicate that conveyors and allied
equipment may be started at any time, that danger exists, and that
personnel must keep clear. These warning signs shall be provided
along the conveyor at areas not guarded by position or location.
(c) Remotely and automatically controlled conveyors and conveyors where

operator stations are not manned or are beyond voice or visual contact
from drive areas, loading areas, transfer points, and other potentially haz-
ardous locations on the conveyor path not guarded by location, position, or
Page 19 of 180
guards shall be furnished with emergency stop buttons, pull cords, limit
switches, or similar emergency stop devices.
(1) All such emergency stop devices shall be easily identifiable in the
immediate vicinity of such locations unless guarded by location,
position, or guards. Where the design, function, and operation of such
conveyor clearly is not hazardous to personnel, an emergency stop
device is not required.
(2) The emergency stop device shall act directly on the control of the
conveyor concerned and shall not depend on the stopping of any other
equipment. The emergency stop devices shall be installed so that they
cannot be overridden from other locations.
(d) Inactive and unused actuators, controllers, and wiring should be removed
from control stations and panel boards, together with obsolete diagrams,
indicators, control labels, and other material that might confuse the
operator.
5.11.3 Safety Devices. All safety devices, including wiring of electrical safety
devices, shall be arranged to operate such that a power failure or failure of
the device itself will not result in a hazardous condition.
5.11.4 Emergency Stops and Restarts. Conveyor controls shall be so arranged

that, in case of emergency stop, manual reset or start at the location where
the emergency stop was initiated shall be required for the conveyor(s) and
associated equipment to resume operation.
Before restarting a conveyor that has been stopped because of an

emergency, an inspection of the conveyor shall be made and the cause of
the stoppage determined. The starting device shall be locked or tagged out
before any attempt is made to remove the cause of the stoppage, unless
operation is necessary to determine the cause or to safely remove the
stoppage. Refer to ANSI 2244.11982, American National Standard for
Personnel Protection - Lockout/Tagout of Energy Sources - Minimum
Safety Requirements, and OSHA Standard Number 29 CFR 1910.147
"The Control of Hazardous Energy (Lockout/Tagout)."
5.12 Operation
(a) Only a trained person shall be permitted to operate (03) a conveyor. Training
shall include instruction in operation under normal conditions and emergency
situations. This provision does not apply to the interface of the public with
conveyors intended for public use, such as at checkout counters.
(b) Where safety is dependent upon stopping devices or starting devices or both,
they shall be kept free of obstructions to permit ready access.
(c) The area around loading and unloading points shall be kept clear of
obstructions that could endanger personnel.
Page 20 of 180
(d) No person shall ride on a conveyor, except on a slow-moving assembly

conveyor 0.4 m/s (80 ft/min) maximum or on a conveyor that incorporates a
station specifically designed for operating personnel.
(e) Personnel working on or near a conveyor shall be instructed as to the location

and operation of pertinent stopping devices.
(f) A conveyor shall be used to transport only loads it is designed to handle safely.
(g) Under no circumstances shall the safety characteristics of the conveyor be

altered if such alterations would endanger personnel.
(h) Routine inspections and corrective maintenance measures shall be conducted

to ensure that all guards and safety features are retained and function properly.
(i) Personnel should be alerted to the potential hazard of entanglement in

conveyors caused by items such as long hair, loose clothing, and jewelry.
(j) Conveyors shall not be maintained or serviced while in operation unless proper
maintenance or service requires the conveyor to be in motion. In this case, per-
sonnel shall be made aware of the hazards and how the task may be safely
accomplished.
5.13 Transfer, Loading, and Discharge Points
(a) At transfer, loading, and discharge points where unconfined and uncontrolled
free fall of material can result from flooding, ricocheting, overloading, trajectory,
leakage, or a combination thereof, such unconfined and uncontrolled free fall of
material shall be prevented if it would create a hazard to personnel.
(b) In the absence of a guard or barrier specifically erected to protect personnel,

warnings shall be provided to restrict unauthorized personnel from entering
hazardous loading, unloading, and transfer areas.
5.14 Hoppers and Chutes
(a) All openings to hoppers and chutes shall be guarded to prevent personnel from
accidentally falling or stepping into them or allowing any part of their body to
make contact with conveyors below them. Where guards are not practical,
warning signs shall be posted. If the hopper or chute is equipped with a grating
to protect against contacting the conveyors below, such grating will be
considered as sufficient guarding provided that one dimension of the opening
does not exceed 50 mm (2 in.).
(b) Dump hoppers having the hopper flush with the floor and which by their use
cannot be guarded shall be equipped with grating having a maximum opening
of 50 mm (2 in.) and shall be heavy enough to withstand any load of personnel
or trucks, etc., that may be imposed on it. If the openings in the grating are
larger or if no grating is provided, temporary railing guard shall be placed
around ground level hoppers when dumping operations are not in progress.
During dumping operations, warning signs shall be placed in conspicuous
locations warning personnel of an open pit. If there is a need to give operators
Page 21 of 180
of trucks, loaders, or bulldozers a reference to the hopper location, guide posts

shall be used.
5.15 Fire Safety
This Standard is not intended to address fire-related considerations. Applicable

national, state, and local codes should be complied with.
6 SPECIFIC SAFETY STANDARDS3
6.1 Belt Conveyors - Fixed in Place 6.1.1 Safety Considerations
(a) Nip and shear points shall be guarded. Typical locations are:
(1) at terminals, drives, take-ups, pulleys, and snub rollers where the belt
changes direction
(2) where belts wrap around pulleys
(3) at the discharge end of a belt conveyor
(4) on transfers and deflectors used with belt conveyors
(5) at take-ups
(b) It is not the intent of this requirement to provide guarding along the conveyor
length where the belt rides on the carrying or return rollers.
(c) Take-up mechanisms may be guarded as an entity by placing standard railings

or fencing around the area with suitable warning signs, as an alternative to
guarding individual nip and shear points.
(d) On overland conveyors, audible or visual (or both) signaling devices for
warning conveyor initiation shall be required only at the transfer, loading, and
discharge points, or at those points where personnel are normally stationed.
(e) On long overland belt conveyors where a pedestrian overpass or underpass is

required, they shall be installed at intervals consistent with usage, normally not
to exceed 300 m (1,000 ft).
6.1.2 Operation and Maintenance
(a) Only trained personnel shall track a conveyor belt, which must be done while the
conveyor is operating.
(b) The practice of applying a belt dressing or other foreign material to a rotating
drive pulley or a conveyor belt is hazardous and should be avoided.
(c) The use of portable emergency stop controllers in lieu of permanently installed
pull cords, push button stations, etc., shall be permitted for maintenance
personnel who patrol overland conveyors. At those points where personnel are
normally stationed, the conveyors shall be equipped with permanently installed
pull cords or similar stop controllers.
6.2 Bucket Conveyors
6.2.1 Guarding
(a) Guards shall be provided at points where personnel could come in contact with
cables, chains, belts, and runways of exposed bucket conveyors.
Page 22 of 180
(b) Inspection doors or maintenance doors or both should include signs warning of
possible danger if opened or removed while the conveyor is in operation.
6.3 Chain Conveyors
6.3.1 Safety Considerations

(a) Chain conveyors, by necessity, have moving chains that cannot be enclosed
without impairing the function. They shall be provided with warning signs or
personnel barriers, unless guarded by location.
(b) Where a chain conveyor is raised and lowered as a transfer mechanism,
mounted within another conveyor, and where enclosure would impair the
function, warning signs or personnel barriers shall be provided, unless guarded
by location.
6.4 En Masse Conveyors
6.4.1 Safety Considerations. En masse conveyors are not considered as free standing
and are to be braced at intervals indicated by the manufacturer. Eccentric platform
loads or other lateral loads may require lateral bracing or other bracing or both.
6.4.2 Guarding. Inspection doors or maintenance doors or both should include signs
warning of possible danger if opened or removed while conveyor is in operation.

(a) Where flight cleaning or casing cleaning or both are required, they shall be
performed by trained personnel, with conveyor power supply locked out.
Special attention may be required at feed and discharge points.
(b) When coupling or uncoupling the en masse conveyor line, the line shall be
restrained to prevent injury through the uncontrolled travel of the broken line.
6.5 Flight and Apron Conveyors - Bulk Material
6.5.1 Safety Considerations. Inclined apron conveyors shall be equipped with lifting
blades when the conveyor inclination exceeds the angle of slide of the design
material.
6.5.2 Operation and Maintenance. At installation, flight and apron conveyors should be
"jogged" or hand run through at least one complete revolution to check design
clearances prior to running under automatic power.
Flight and apron conveyors handling sticky materials, which tend to build up, shall
be cleaned as often as required for safe operation.
6.6 Inclined Reciprocating Conveyors

(a) Means shall be provided to prevent hazard to personnel in the event of
mechanical or electrical failure. The carrier must be equipped with backstop
devices sufficient to stop and to hold the carrier and load.
(b) Over-travel devices shall be provided where necessary to minimize potential
for injury to personnel.
Page 23 of 180
(c) Riding the conveyor shall be forbidden to all personnel. Warning signs to this
effect shall be prominently posted at each point of access and each point of
operation.
6.6.2 Guarding
(a) The conveyor shall be guarded so as to prevent injury from inadvertent
physical contact.
(b) The conveyor housing shall be equipped with doors or an equivalent means at
each manual loading and unloading station, interlocked so that they can be
opened only when the carrier has stopped at that level and such that the
carrier cannot be actuated until they are closed.
(c) Inclined reciprocating conveyors that automatically receive and discharge
material may have interlocked doors as in (b) above or, as an alternative, may
be guarded by a suitable enclosure extending from the path of the moving
carrier.
(d) Where the application requires that personnel walk onto the carrier to load or
unload material the carrier shall be provided with standard railings, snap
chains, or equivalent, across the loading /unloading side(s). Snap chains shall
be at least 39 in. at their lowest point.
(e) Controls shall be installed or located so they cannot be actuated by a person
on the carrier.
6.7 Live Roller Conveyors - Belt or Chain Driven

(a) Nip points occur between chain and sprockets on chain driven live roller
conveyors.
(b) Nip points can occur between belt and carrier rollers on belt driven live roller
conveyors.
(c) Nip points occur at terminals, drives, take-ups, idlers, and snub rollers where
the belt changes direction. A return belt idler does not require guarding.
(d) Nip points occur on transfers and deflectors used with live roller conveyors.
(e) Shear points occur at automatic take-ups; they shall be guarded.
6.7.2 Guarding
(a) On chain driven live roller conveyors, unless guarded by location or position,
the nip point between chains and sprockets shall be enclosed, to prevent entry
of hands, fingers, or other parts of the body into a point of hazard by reaching
through, over, under, or around the guard.
(b) On belt driven live roller conveyors, nip points between the belt and roller may
be considered guarded if the load carrying rollers are spaced so as to prevent
access, if plates or rods are placed between rollers, if pop-out rollers are used
as load carrying rollers, or if other suitable guarding is used, such as guarding
by location.
6.8 Mobile Conveyors

(a) Mobile conveyors shall be provided with a brake, rail damp, or other position
locking device for each motion, such as, but not limited to, luffing, slewing, and
traversing, where movement would present a hazard.
Page 24 of 180
(b) Limit switches shall be provided on rail mounted mobile conveyors to limit the
travel within design limits. Rail stops shall be provided beyond the design travel
limits to physically stop the mobile conveyor in case of over travel.
(c) Sweeps shall be provided on all rail mounted mobile conveyors to deflect
objects ahead of the nip points between wheels and rails where a hazard to
personnel would result without the sweep.
(d) A mobile conveyor shall be designed to be stable against runaway or
overturning under normal conditions of operation. Resting a portion of a mobile
conveyor on the ground, a pile, or on any other support shall not cause
instability of the machine.
6.8.2 Guarding
(a) Where power to electrically powered mobile conveyors is provided by trolley or
rail, these conductors shall be guarded in such a manner as to prevent
accidental contact by personnel.
(b) Access stairways, ladders, and platforms shall be designed and located so as
to avoid hazardous shear or nip points between sections of structures that in
operation move relative to each other.

(a) When a mobile conveyor exposed to high wind conditions creates a hazard to
personnel, normal operation shall cease and, if necessary, the conveyor shall
be moved to a parking position and secured.
(b) When an operator is required on a mobile conveyor, a platform or cab shall be
constructed for his protection. The conveyor shall be designed so that, when
the operator is on the platform engaged in the normal performance of his
duties, he will be protected from injury.
(c) Where operation is such that there is danger of movement of the mobile
conveyor into the stockpile or any other obstacle, a detector shall be provided
to stop the conveyor movement.
6.9 Portable Conveyors, Extendible Belt Conveyors, and Car Unloaders

(a) The raising and lowering mechanism for the boom of a portable conveyor shall
include in its design, or be provided with, a safety device that will hold the
boom at any rated angle of inclination.
(b) A powered extendible conveyor shall be equipped with a device located on the
outermost boom end that shall stop extension of the conveyor when contact is
made with the device as may be required to protect personnel.
(c) An extendible conveyor shall be equipped with momentary contact push
buttons without holding circuits to activate powered booms.
(d) Portable conveyors shall be stable when used within the manufacturer's rating
so that the conveyor will not topple when in use or when being moved in the
manner for which it was intended. When the portable conveyor must be lashed
to prevent movement or overturning in high winds, a warning sign indicating
the necessity shall be clearly posted.
(e) Guarding by location shall be determined with the boom in its lowest position.
Page 25 of 180
6.10 Pusher Bar Conveyors

(a) If a hazard exists where the bar passes through the bed at the discharge end,
suitable guards or warnings shall be provided at this point.
(b) Loads on the incline shall have pushers of adequate height above the bed or
have top restraining members.
(c) All chains shall be guarded by suitable means, including warning signs, to
prevent accidental contact with the moving chain.
(d) In a pusher bar conveyor having a roller bed, where the relationship between
the height of the bar and the spacing of the rollers creates a hazard, adequate
guarding shall be provided.
(e) When a shear point exists between the return pusher bar and a frame
member, guarding shall be provided.
(f) When the conveyor is automatically loaded, an automatic spacer shall be
provided to ensure feeding the loads ahead of the pusher bars where a hazard
to personnel could exist.
(g) When a pusher bar conveyor discharges to another conveyor, means shall be
provided to stop the pusher bar conveyor in the event the receiving conveyor
cannot accept another load.
6.11 Roller and Wheel Conveyors

(a) Unit or package speeds that could create a safety hazard shall be avoided by
limiting the length of the pitched run or by using speed retarders, brakes, or
other means that effectively provide the control needed.
(b) Personnel shall not be allowed to walk or step on free turning rollers or wheels.
Suitable means, such as tread plates, can be used between the rollers as a
walking surface for designated operators in the performance of their duties.
6.11.2 Operation and Maintenance. Rollers and wheels shall be free running to prevent
unintentional diverting of units being conveyed when such a diverted unit could
create a hazard to personnel.
6.12 Screw Conveyors

(a) Screw conveyors shall not be operated unless the conveyor housing
completely encloses the conveyor moving elements, and power transmission
guards are in place, except as provided in (b) and (c) below.
(b) 1f the conveyor must have an open housing as a condition of its use and
application, the entire conveyor is then to be guarded by a railing or fence,
unless guarded by location.
(c) Feed openings for shovel, front end loader, or other manual or mechanical
equipment shall be constructed in such a way that the conveyor screw is
covered by grating. If the nature of the material is such that a grating cannot
be used, then the exposed section of the conveyor is to be guarded by a
railing and there shall be warning signs posted.
Page 26 of 180
6.13 Shuttle Conveyors, Belt Trippers, and Transfer Cars

(a) These conveyors shall be provided with a brake, rail clamp, or other position
locking device.
(b) Means shall be provided to limit travel. Stops shall be provided beyond the
normal travel limits to stop the conveyor in case of over travel.
(c) When the conveyor and its path are obstructed from view of the controlling
operator, the conveyor shall have a device to warn of its movement or
provide other means to ensure personnel safety in the area.
(d) Sweeps shall be provided for all moving cars, trippers, or shuttles to deflect
objects ahead of pinch points between wheels and rails, where a hazard to
personnel would result without the sweep.
(e) Although all nip and shear points shall be guarded, it is not the intent of this
requirement to provide guards where the belt rides on the idlers.
(f) Trippers or shuttles may discharge into silo or bunker openings, with or
without seals. In either case, openings shall be provided with grating to suit
the material being handled, and the width of the openings shall not be large
enough to permit personnel to fall through. Where material size requires
openings that would permit personnel to fall through, the openings shall be
protected by other means.
(g) Where power is electrically provided via trolley or rail, these power
conductors shall be guarded in such a manner as to prevent accidental
contact by personnel. In explosive areas, explosion-proof equipment and
cable reels shall be used instead of trolley and rail.
(h) When a person is required to move with the shuttle, tripper, or transfer car, a
work station shall be provided for his/her protection.
6.14 Skip Hoists - Bulk Materials

(a) Limit switches shall be provided to establish limits of travel of the skip bucket.
Additional switches shall be provided to interrupt the power supply and
actuate the hoist brake whenever the skip bucket, through failure of the
design travel limit switches or for any other reason, exceeds the design travel
limit by a predetermined safe distance.
(b) Slack cable switches shall be provided and so arranged that whenever the
skip hoisting rope or the counterweight hoisting rope develops slack or loses
tension due to sticking in the guides, over travel, or for any other reason,
power to the drive will be cut off and the brake will be set.
(c) Riding the skip bucket by personnel shall be forbidden.
6.14.2 Guarding
(a) All sheaves shall be fitted with sheave guards to prevent the wire rope from
coming off the sheaves under a slack cable or similar condition.
(b) The guarding of the wire rope and drum on the hoist is normally not practical
due to fleet angle requirements. If the hoist unit is located in an area that is
generally accessible, then a complete wire mesh or similar guard shall be
placed around the hoist. This guard is not required when guarded by location.

(a) The following wearing parts should be regularly and frequently inspected by
qualified maintenance personnel and should be maintained regularly or
Page 27 of 180
replaced when the degree of wear indicates possibility of failure before the
next inspection:
(1) brake shoes and brake operating parts
(2) hoisting ropes, clamps, and attachments
(3) sheaves, particularly head sheaves
(4) tracks, wheels, and mechanisms
(5) limit switches and slack cable device
(b) Whenever the brake or any parts of the drive train between the brake and the
drum shaft are being repaired or replaced, the skip bucket and counterweight
shall be blocked in their guides.
6.15 Slat Conveyors and Roller Slat Conveyors
6.15.1 Safety Considerations. A slat conveyor can present a shear point when the gap
between the slats is great enough to permit access to cross members below the
slats. At these points all members should be a safe distance away from the slats,
or a continuous pan under the slats should be provided.
6.15.2 Guarding. A hazard exists at the tail end of a slat conveyor in which the slats are
above the center line of the chain. The gap between slats closes when the slats
reach the top surface of the conveyor. This area should be guarded. If the
material flow enters over the tail sprocket, making guards impractical, a warning
sign should identify the hazard.
6.16 Suspended Vertical Tray Conveyors

(a) Means shall be provided to sense overloads where these loads could cause
failure and injury to personnel.
(b) Automatic loading and unloading devices are recommended to prevent placing
of any parts of the human body into the path of vertically traveling carriers.
6.16.2 Guarding
(a) The conveyor shall be installed in an enclosed shaft way or housing to prevent
injury from inadvertent physical contact with moving parts of the equipment.
Access doors to the shaft way or housing shall be secured so that only
authorized service personnel may enter.
(b) For suspended vertical tray conveyors designed so that the pendant tray, car,
or carrier comes to a stop during manual loading or unloading, the conveyor
housing should be equipped with interlocked doors or equivalent safety
barriers at each manual loading and unloading station. The doors shall be
mechanically or electrically interlocked to the operation of the conveyor so that
they can be opened only when the pendant tray, car, or carrier has stopped,
and so that the pendant tray, car, or carrier cannot be moved until they are
closed.
(c) Suspended vertical tray conveyors designed to automatically receive and
discharge material may have interlocked doors as in (b) above or, as an
alternative, may be guarded by a suitable enclosure extending on all sides a
safe distance from the path of the moving pendant trays, cars, or carriers.
Page 28 of 180
6.17 Tow Conveyors
6.17.1 Tow Conveyors - In the Floor/Overhead
6.17.1.1 Safety Considerations

(a) A clearance space for personnel shall be provided between the side of
a cart, or between any load overhanging the side of a cart, and any
fixed or moving object.
(b) The cart path shall be identified by a floor stripe parallel to the cart
path, one line on each side, located a safe distance from the edge of
the cart or overhanging load.
(c) Where wall openings or other conditions do not permit a safe
clearance, the reduced clearance area shall be marked with
appropriate warnings.
(d) Where a cart may change its direction without warning, such as
switching off the main line into a transfer conveyor or a spur, this area
shall be marked with an appropriate warning such as diagonal stripes
on the floor within the clearance lines.
(e) Where carts start automatically, a warning is required.
(f) Means shall be provided to allow the operator to disengage the tow pin
from the conveyor pusher without being in front of the cart.
6.17.1.2 Guarding
(a) Provisions shall be made to prevent runaway carts from exiting the
ramp zone and entering work areas.
(b) Ramps with traffic aisles shall have a barrier of sufficient strength and
height to prevent a runaway cart from entering the traffic aisle.
(c) Ramps without traffic aisles shall have warning signs to warn personnel
not to enter.
(d) Means shall be provided to maintain the stopped position of a ramp
conveyor or carts under maximum rated load condition.
(e) Where there is a projection above the floor, the projection and adjacent
area shall be identified by appropriate diagonal stripes or warning
signs, or both. This identification shall particularly apply to devices that
project intermittently at unpredictable times.
6.17.2 Tow Conveyors - Public Use Intended
6.17.2.1 Safety Considerations

(a) Means shall be provided to sense overloads where these loads could
cause injury.
(b) Loading and unloading areas shall be provided with means to detect
personnel on or in unauthorized proximity to the conveyor and
automatically stop or prevent motion.
(c) Means shall be provided to physically restrict people from the path of
the towed vehicle.
(d) Riding or walking on the conveyor or towed vehicle shall be forbidden.
Warning signs to this effect shall be prominently posted at each point of
access and each control station.
Page 29 of 180
6.17.2.2 Guarding.
Where a parted chain, cable, belt, tow pin, or other linkage would permit a
runaway condition on an incline or decline, anti-runaway/backstop devices
shall be provided.
6.18 Trolley Conveyors and Power and Free Conveyors

(a) In areas where the parted chain, cable, or other linkage would permit a
runaway condition on an inclined or declined section, and where personnel are
present, anti-runaway devices shall be provided. The conveyor path may be
arranged so that travel of the uncontrolled conveyor will be arrested before it
enters an area where personnel are present.
(b) In areas where personnel perform work on the load of a moving conveyor, and
guards would impair the workers' performance, the load shall be cradled,
hooked, bolted, or otherwise attached to the carrier.
6.18.2 Guarding
(a) Nip points occur at traction wheels, sprockets, caterpillar drives, and roller
turns, and shall be guarded unless guarded by location.
(b) The telltale effect of the moving conveyor components serves as a warning
device and permits unguarded nip or shear points at heights of less than 2.44
m (8 ft).
(c) Automatic stops or closures shall prevent a trolley or trolleys from moving off
the track during the portion of a cycle when any track end is not aligned with its
mating member.
(d) Hoisting equipment for lift sections or drop sections or both shall stop or control
the vertical motion in the event of power failure.
(e) On inclined or declined conveyors or sections, where personnel are present
and there may be an occurrence of uncontrolled movement of a free trolley,
arresting devices shall be provided. A rigid pusher dog on the power chain with
positive carrier engagement shall be considered an acceptable means, or the
conveyor path may be arranged so that travel of the uncontrolled free trolley,
carrier, or load, or combination thereof, will be arrested before it enters the
personnel area.
(f) Guards shall be provided to restrict unauthorized personnel from entering
hazardous loading, unloading, and transfer areas. When guarding is not
feasible, dear and legible warnings shall be provided.
(g) Access to lift or drop sections shall be guarded to prevent unauthorized
personnel from entering the area. Warning signs shall be posted where
guarding is not feasible, unless access to lift or drop sections is guarded by
location.
(h) Where conveyors are located above personnel and the possibility exists that
the transported product may fall off from any cause, guards (spill guards) shall
be provided.
6.19 Vertical Articulated Conveyors

.
(a) Control system shall include means to prevent jamming or spilling objects if the
absence of such controls could produce a hazards to personnel.
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(b) Means shall be provided to stop the conveyor in the event a jam occurs where
injury to personnel would otherwise result.
6.19.2 Guarding
(a) The conveyor shall be enclosed to prevent injury from inadvertent physical
contact with the moving parts of the equipment.
(b) The entry and exit openings in the enclosure shall be guarded by extending the
enclosure side guards a safe distance from the path of the vertically moving
carrier. A top cover shall be provided to form a tunnel, if practical.
6.20 Vertical Chain Opposed Shelf Type Conveyors
6.20.1 Safety Considerations.

Overload devices shall be furnished to stop the conveyor in the event a jam occurs
where injury to personnel would otherwise result
6.20.2 Guarding
(a) The conveyor shall be housed so as to prevent injury from inadvertent physical
contact with the moving parts of the equipment.
(b) The conveyor housing should be equipped with doors or equivalent device at
opened only when the carrier has stopped and the carrier cannot be actuated
until they are closed.
(c) Vertical chain opposed shelf conveyors that automatically receive and
alternative, may be guarded by a suitable enclosure extending from the path of
the moving carrier platform.
6.21 Vertical Reciprocating Conveyors

(a) Means shall be provided to prevent hazard to personnel in the event of
mechanical or electrical failure. The carrier must be equipped with backstop
devices sufficient to stop and to hold the carrier and load.
(b) Over-travel device(s) shall be provided where necessary to minimize potential
for injury to personnel.
(c) Riding the conveyor shall be forbidden to all personnel. Warning signs to this
effect shall be prominently posted at each point of access and each point of
operation.
6.21.2 Guarding
(a) The conveyor shall be guarded so as to prevent injury from inadvertent
physical contact.
(b) The conveyor housing shall be equipped with doors or an equivalent means at
opened only when the carrier has stopped at that level and such that the
carrier cannot be actuated until they are closed.
(c) Vertical reciprocating conveyors designed to automatically receive and
alternative, may be guarded by a suitable enclosure extending from the path of
the moving carrier.
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(d) Where the application requires that personnel walk onto the carrier to load or
unload material, the carriers shall be provided with standard railings, snap
chains, or equivalent across the loading/unloading side(s). Snap chains shall
be at least 39 in. at their lowest point.
(e) Controls shall be installed or located so they cannot be actuated by a person
on the carrier.
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Conveying System
Control Narrative
Bechtel / Xstrata – Antapaccay Project
Tintaya Expansion
CONVEYING SYSTEM
CONTROL NARRATIVE
ThyssenKrupp Robins Inc.
Denver, Colorado, USA
B For Approval KPW MGG JC 18/Mar/2011
A Preliminary / For Internal Review KPW MGG JC 25/Feb/2011
Rev. Description Prepared by Revised by Approved by Date
Rev B i 18-Mar-11
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Contents
1 INTRODUCTION ..................................................................................................................... 37
1.1 System Description ..................................................................................................................... 37
1.2 Conveyors Description................................................................................................................ 39
1.2.1 Sacrificial Conveyor ............................................................................................... 39
1.2.2 Overland Conveyor ................................................................................................ 39
1.2.3 Control System Description ................................................................................... 40
2 Local Control Stations ............................................................................................................ 42
3 Control Modes ....................................................................................................................... 43
3.1 Remote Mode ............................................................................................................................. 43
3.1.1 Remote-Auto (Automatic Mode)........................................................................... 43
3.1.2 Remote – Manual (Automatic Local) ..................................................................... 45
3.2 Local Mode (Local Manual) ........................................................................................................ 46
3.3 Maintenance Mode .................................................................................................................... 47
3.4 Warnings and Alarms ................................................................................................................. 47
4 CVB-0001 operating philosophy ............................................................................................ 47
4.1 Reducer....................................................................................................................................... 47
4.2 Brake System .............................................................................................................................. 48
4.3 Drive motor ................................................................................................................................ 49
4.4 Operating Speeds ....................................................................................................................... 51
4.5 Pulleys......................................................................................................................................... 52
4.6 Vertical Gravity Take-up ............................................................................................................. 52
4.7 Metal Detector ........................................................................................................................... 52
4.8 Belt Scale .................................................................................................................................... 53
4.9 Belt Rip Detection System .......................................................................................................... 53
4.10 Speed Sensor .............................................................................................................................. 53
4.11 Emergency Pull Cord Switches ................................................................................................... 54
4.12 Belt Misalignment Switches ....................................................................................................... 54
4.13 Plugged Chute Switches ............................................................................................................. 55
4.14 Warning Horns and Strobe Lights............................................................................................... 55
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4.15 Belt Tension Monitor .................................................................................................................. 55

4.16 Dust Control System (by Bechtel) ............................................................................................... 56
5 CVB-002 Operating Philosophy ............................................................................................. 56
5.1 Brake System .............................................................................................................................. 56
5.2 Drives .......................................................................................................................................... 57
5.3 Operating Speeds ....................................................................................................................... 62
5.4 Pulleys......................................................................................................................................... 63
5.5 Horizontal Winch Take-up .......................................................................................................... 63
5.6 Belt Rip Detection System .......................................................................................................... 64
5.7 Speed Sensor .............................................................................................................................. 65
5.8 Emergency Pull Cord Switches ................................................................................................... 66
5.9 Belt Misalignment Switches ....................................................................................................... 66
5.10 Stock Pile Level Switches ............................................................................................................ 66
5.11 Warning Horns and Strobe Lights............................................................................................... 67
5.12 Belt Tension Monitor .................................................................................................................. 67
5.13 Dust Control System (by Bechtel) ............................................................................................... 68
6 Interlocks and Permissives .................................................................................................... 68
6.1 Conveyor CVB-001 ...................................................................................................................... 68
6.2 Conveyor CVB-002 ...................................................................................................................... 69
7 Warnings and Alarms ............................................................................................................ 70
7.1 Conveyor CVB-001 ...................................................................................................................... 70
7.2 Conveyor CVB-002 ...................................................................................................................... 72
7.3 CVB-002 Winch ........................................................................................................................... 75
7.4 Power Monitoring ...................................................................................................................... 76
7.5 Fire Alarms .................................................................................................................................. 77
8 Data Interfaces ...................................................................................................................... 77
8.1 CVB-001 Drive VFD ..................................................................................................................... 78
8.1.1 Communication loss .............................................................................................. 79
8.1.2 Emergency Stop ..................................................................................................... 79
8.2 CVB-002 Drive Controller ........................................................................................................... 79
8.2.2 Emergency Stop ..................................................................................................... 81
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8.3 CVB-002 Winch VFD ................................................................................................................... 81

8.4 CVB-002 Brakes Controller ......................................................................................................... 82
8.5 Pull cord controller ..................................................................................................................... 82
8.5.1 Conveyor Control Panel ......................................................................................... 82
8.5.2 Conveyor Station c/w pull-cord switch, horn and strobe light ............................. 83
8.5.3 Conveyor Station c/w pull-cord switch ................................................................. 83
8.5.4 Conveyor Tail End Unit .......................................................................................... 83
8.5.5 Belt Wander Stations ............................................................................................. 83
8.6 Belt scale..................................................................................................................................... 83
8.7 Power Monitoring ...................................................................................................................... 84
8.8 Miscellaneous devices ................................................................................................................ 84
8.9 DCS.............................................................................................................................................. 85
8.9.1 Communications configuration ............................................................................. 85
8.9.2 Data tables ............................................................................................................. 85
8.9.3 Communications monitoring ................................................................................. 91
9 Safety Systems ....................................................................................................................... 92
9.1 Emergency Stop circuits ............................................................................................................. 92
9.1.1 Safety relay ............................................................................................................ 92
9.2 Warning strobes and horns ........................................................................................................ 92
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1 INTRODUCTION
This document describes the control and operation philosophy for the overland conveying
system at the Antapaccay mine located at Cuzco, Peru. The overland conveying system is
designed to transport primary crushed copper ore between the Crusher Station and the Stock
Pile. It is designed for a maximum tonnage of 5,263 mtph.
The system control is performed by a main PLC interconnected to other system via various
networks. The system is designed to be operated by a single operator from one of two operator
graphic stations located in the concentrator and crusher control rooms.
1.1 System Description
The system consists of a Sacrificial Conveyor (0220-CVB-0001) and an Overland Conveyor (0220-
CVB-0002). The Sacrificial Conveyor 0220-CVB-0001 is approximately 135 meters long with 6
meters of lift. The Overland Conveyor 0220-CVB-0002 is approximately 6,500 meters long with
220 meters of lift.
Sacrificial Conveyor 0220-CVB-0001 is powered by one gearbox that is driven by one 250kW,
VFD controlled drive motor at the head end. Sacrificial Conveyor 0220-CVB-0001 will operate
continuously and provide material to Overland Conveyor 0220-CVB-0002 as long as the
Overland Conveyor 0220-CVB-0002 continues to operate. If an unplanned stop of Conveyor
0220-CVB-0002 occurs, then Conveyor 0220-CVB-0001 must be stopped immediately.
The Overland Conveyor is powered by Cycleconverter Speed Drives (CSD) and is equipped with
mechanical brake systems located at its tail end pulley and at the primary and secondary driven
pulleys.
Starting and stopping of the conveyor system will be done sequentially. Starting will begin with
the Overland Conveyor 0220-CVB-0002 and end with the Sacrificial Conveyor 0220-CVB-0001
(the Apron Feeder MRA-MHFA-00001, by others, will start after 0220-CVB-0001). Stopping will
be the reverse sequence of starting. For planned stops of the conveyor system plugging of the
transfer chutes is not a concern. In emergency stop situations the chutes will be filled with
excess material because the stopping times of all conveyors are not the same. To prevent
excessive spillage upon startup, the start signal for the Sacrificial Conveyor 0220-CVB-0001 will
not be sent until the Overland Conveyor 0220-CVB-0002 has reached full speed and been
running for sufficient time that the transfer chute is free from excess material and can accept
the maximum drift capacity of the Sacrificial Conveyor 0220-CVB-0001. The start signal for the
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Apron Feeder MRA-MHFA-00001, by others, should be sent when the Sacrificial Conveyor 0220-
CVB-0001 has been running at full speed for sufficient time to empty 100% volume of the
transfer chute between the two systems (full speed for 30 seconds).
Dust collector systems will be used to control the dust emission. These systems will be supplied
by Bechtel.
A general overview of the system, together with the belt profiles and drive configurations for
conveyors 0220-CVB-0001 and 0220-CVB-0002 are provided in the general arrangement
drawings. Additional information about these conveyors can also be found in the P&ID
drawings. Below is a list of reference drawings:
1830 mm (72 in.) SACRFICIAL CONVEYOR 0220-CVB-0001

• 200AR816 GENERAL ARRANGEMENT, SH.1
TRANSFER TOWER (0220-CVB-0001 TO 0220-CVB-0002)

• 300AR816 GENERAL ARRANGEMENT, SH. 1
• 302AR816
1372mm (54 in.) OVERLAND CONVEYOR 0220-CVB-0002

• 400AR002 GENERAL ARRANGEMENT, SH.1 (TAIL)
• 401AR002 GENERAL ARRANGEMENT BOM
• 402AR002 GENERAL ARRANGEMENT, SH.2 (TAIL)
• 403AR002 GENERAL ARRANGEMENT, SH.3 (BRIDGE)
• 404AR002 GENERAL ARRANGEMENT, SH.4 (HEAD)
• 407AR002 GENERAL ARRANGEMENT, SH.14 (DRIVE)
• 409AR002 GENERAL ARRANGEMENT, E-HOUSE
• 415AR002 GENERAL ARRANGEMENT, SH. 12
P&ID's
• 1002E021 P&ID/01
• 1002E022 P&ID/02
• 1002E023 P&ID/03
• 1002E024 P&ID/04
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• 1002E025 P&ID/05
• 1002E026 P&ID/06
• 1002E027 P&ID/07
• 1002E028 P&ID/08
• 1002E029 P&ID/09
• 1002E030 P&ID/10
1.2 Conveyors Description
1.2.1 Sacrificial Conveyor
The Sacrificial Conveyor 0220-CVB-0001 has an approx. length of 135 m and has a design
capacity of 5,263 mtph. It runs at a design belt speed of 2.9m/s. This conveyor receives material
from the Apron Feeder (MRA-MHFA-00001, by others) and transports material to the Overland
Conveyor 0220-CVB-0002.
Sacrificial Conveyor 0220-CVB-0001 is equipped with one 250 kW Squirrel Cage Motor with a
250 kW Variable Frequency Drive and a mechanical thruster brake.
The VFD and motor are designed to provide 200% of their nominal torque for up to 30 seconds
to accommodate short term motor overload without stopping the conveyor.
The belt tension of Sacrificial Conveyor is controlled by a gravity take-up located at the head
station.
The belt is equipped with a belt scale, mechanical belt rip switches and a metal detector in
addition to other accessories.
1.2.2 Overland Conveyor
The Overland Conveyor 0220-CVB-0002 has an approx. length of 6500 m and has a design
capacity of 5,263 mtph. It runs at a design belt speed of 6.2m/s. This conveyor receives material
from 0220-CVB-0001 and transports material to a stock pile. Level indicator switches at the
head end of 0220-CVB-0002 will control the feed of the conveyor system. If the level is too high
the conveyor system will receive a stop signal.
The Overland Conveyor 0220-CVB-0002 is equipped with two 3800 kW Synchronous Motors,
3800 kW and 63rpm (design speed of pulley is 63rpm to have 6.2m/s belt speed) with two 3800
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kW Cycleconverter Speed Drives (CSD) and two mechanical disk brake systems. The drives and
control system are manufactured by Siemens.
The CSD drives are designed to provide 115% of their nominal torque continuously as needed.
The drives are used to accelerate and stop the conveyors under normal conditions.
Belt tension is controlled by a dynamic take-up winch used to position the take-up carriage.
1.2.3 Control System Description
The control system consists of one main PLC with s remote I/O stations located along the
conveying system route and the Crusher electrical room. The primary control will be from one
of two client DCS operator stations located in the crusher and concentrator control rooms. This
DCS control system is supplied by Bechtel.
Two graphical HMIs are provided for diagnostic and maintenance purposes. One is located in
Electrical House 0220-CVB-0001 at the sacrificial conveyor, and the other is located in Electrical
House 0220-CVB-0002 at the overland conveyor.
Each drive is also with a small operator interface panel for local maintenance and diagnostics.
Both conveyors and related devices have local control stations, typically with selectors and
pushbuttons for local operation.
All the system control and monitoring functions are performed by the PLC. The control and
monitoring of the Siemens SINAMICS SL150 Cycleconverter Speed Drives for the Overland
Conveyor 0220-CVB-0002 are performed by Siemens SIMOTION controller inside each
Cycleconverter Speed Drive.
The PLCs, the brake instrumentation, and all the critical field instrumentation are powered by
UPS’s to maintain control of the system in case of AC power failure.
All e-stop switches and pull cords are hardwired to safety relays independent of the PLC to
ensure fail-safe operation in the case of an emergency.
1.2.3.1 Control PLC
The main PLC rack is located at Electrical House 0220-ERR-0001 and has both main and
redundant S7-400 CPUs with separate power supplies. The main and redundant PLCs
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communicate with the DCS via separate Ethernet ring networks. Both PLCs will be mounted on
the same 18 slot rack, on separate halves.
Both main and redundant CPUs connect to I/O, drives and other equipment via Profibus DP
control network.
1.2.3.2 Profibus Network
The Profibus network connects the I/O, drives, pull cord system and brake controller to the main
and redundant PLCs via two independent Profibus networks. Each CPU can access the Profibus
network independent of the other. The Profibus network connects to equipment located in
both Electrical Houses.
The I/O, drives, pull cord controller and brake controllers are not redundant. A Profibus DP-Y
link is used to connect to the main and redundant Profibus networks. The I/O racks connect to
the main and redundant networks using independent communication adaptors.
At Electrical House 002, the Profibus network is connected entirely by copper coaxial cable. The
CPUs connect to the equipment in Electrical House 001 via two fiber optic redundant ring
networks. Independent Profibus cards are used in the PLC rack to provide independent access
to the Profibus rings for the main and redundant CPUs.
A power meter is also connected to the Profibus network which monitors the 480V subsystem.
The Profibus network will be configured to communicate at 1.5Mb/s. A schematic of the

Profibus network is shown in drawing 1002E070.
1.2.3.3 Ethernet Network
Communications between the DCS and the PLC is via Ethernet. Dual redundant fiber optic rings
connect the Crusher control room to the PLC. One ring connects to the main CPU and the other
to the redundant CPU. Separate Ethernet cards are used in the PLC rack to provide independent
access to the Ethernet rings for the main and redundant CPUs.
The Ethernet network shall be configured to communicate at 10Mb/s. A schematic of the

Ethernet network is shown in drawing 1002E070.
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2 Local Control Stations
Most equipment will have an LCS stations located in the field. The LCS’s are equipped with
different control selectors and pushbuttons. The following tables show the LCS arrangements:
Associated Description H/O/A E-Stop Stop Start Jog Fwd Normal

Equipment Rev Creep
Tag
HS00532 Conveyor CVB-0001 x x x x
HS00573 Conveyor CVB-0002 (pulley 1) x x x x x x x
HS00575 Conveyor CVB-0002 (tail end) x x x x x x x
HS00576 Conveyor CVB-0002 (pulley 2) x x x x x x x
Associated Description M/A On Fwd Rev

Equipment Off
Tag
M00535 Blower (CVB-0001 drive motor) x x
M00536 Thruster brake (CVB-0001 drive motor) x x
M00522 Recirculation pump (CVB-0001 reducer) x x
Metal Detector (CVB-0001) x x
Belt Scale (CVB-0001) x x
Calibration chain winch (CVB-0001) x x x
M00563 Take-up Winch (CVB-0002) x x x x
Tail end brake system (CVB-0002) x x
Head end brake system (CVB-0002) x x
Motorized belt reel (CVB-0002) x x x
Pulley removal system winch (CVB-0002) x x x
Pulley removal system hoist (CVB-0002) x x x
Table 1: Auxiliary LCS devices
For all LCS stations the H/O/A or M/A selection will be interlocked by the DCS. The LCS’s will be
inactive until the DCS interlock is released. The H/O/A and M/A selectors will be maintained 3
and 2 positions.
The On/Off selectors will be three positions with spring to centre return. Left will be on and
right will be off. The on/off will be momentary signals.
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The emergency stop and stop buttons of the conveyor LCS will always be active regardless of the
DCS interlock or operation mode of the equipment.
The signals from the motors cooling fans and water cooling pumps and fans of the synchronous
motors are sent by the PLC via Profibus. These cooling pumps and fans do not have any Local
Control Station for local or maintenance operation.
3 Control Modes
The control of the system will be by PLC and DCS. The PLC will provide all of the control logic
and the DCS will provide the operator interface. The HMIs at the Electrical Houses will provide
monitoring and maintenance diagnostic features only.
Each drive will have its own small operator panel for commissioning operation and local
diagnostics only.
Two remote operational control modes (Remote-Auto, Remote-Manual), one local control mode
and one maintenance mode are available. These mode selections depend upon the position of
equipment selectors in the field and interlocking by the DCS. These modes are described in the
following sections.
3.1 Remote Mode
All field LCSs must be set to the AUTO position. The DCS interlock for all LCS’s must also be set
to REMOTE.
In remote mode, the conveying system will be controlled in fully interlocked automatic
operation only. This will be the normal operating mode. In remote mode, the conveyors can be
operated in AUTO of MANUAL.
3.1.1 Remote-Auto (Automatic Mode)
The following system states will be defined:
• Stopped
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• Starting
• Running
• Stopping
The following commands will be available from the DCS:
• System pre-start
• System start
• System empty-stop
• System sequence-stop
• System immediate stop
3.1.1.1 System Pre-Start
A system start command initiates the following
• Initialization of the CVB-0002 brake system

• Pre-charging of the CSD drive converters
• Start CVB-0001 reducer pumps
• Start motor and CVB-0001 reducer cooling equipment
3.1.1.2 System Start
The sequence starts with the warning horns and strobe lights on CVB-0001. After a 30 second
delay, the conveyor starts. When the conveyor is confirmed running, the warning horns are
stopped. The sequence continues with CVB-000 after CVB-0001 confirmed running, with the
same process as for CVB-0001.
3.1.1.3 System Empty Stop
When a system empty-stop command is issued, the feeder upstream of CVB-0001 is stopped.
When no material is detected by the belt scale a “conveyor empty” timer is started. When the
time expires the conveyor is stopped. The timer is reset if further material is detected by the
belt scale during the timing sequence.
When CVB-0001 stops an empty timer starts for CVB-0002 to allow CVB-0002 to discharge any
remaining material on the belt. Once this timer has expired, CVB-0002 will start its stopping
sequence.
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When an empty stop is successfully completed a flag is set to record this event which is used to
interlock local operation at creep speed. Refer to the local mode description for further details.
3.1.1.4 System Sequence-Stop
The system sequence stop is identical to the empty sequence stop, except that the system does
not wait for the belt empty condition.
3.1.1.5 System Immediate-Stop
When an immediate-stop command is received from the operator, both conveyors are
commanded to stop with maximum deceleration independently of each other.
3.1.2 Remote – Manual (Automatic Local)
In remote manual, each conveyor can be started and stopped individually. Fully interlocked
operation still applies.
The following conveyor states will be defined:
• Stopped
• Starting
• Running
• Stopping
The following commands will be available from the DCS:
• Conveyor pre-start
• Conveyor start
• Conveyor stop
3.1.2.1 Conveyor Pre-Start
A system start command initiates the following
• Initialization of the CVB-0002 brake system
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• pre-charging of the CSD drive converters

• CVB-0001 reducer pumps
• Motor and CVB-0001 reducer blowers
3.1.2.2 Conveyor Start
The sequence starts with the warning horns and strobe lights on the conveyor. After a 30
second delay, the conveyor starts. When the conveyor is confirmed running, the warning horns
are stopped.
3.1.2.3 Conveyor Stop
When a system stop command is issued the conveyor drive system is commanded to stop.
3.2 Local Mode (Local Manual)
Local mode is selected at the equipment local control station in the field. The selection of local
in the field is also interlocked by the DCS. The local mode will only be active when the LCS is set
to HAND and the DCS interlock for the conveyor LCS is set to LOCAL.
If PLC-DCS communications is lost, the PLC will allow local mode without DCS interlocking.
The local mode provides the ability to run each conveyor and major components independently
for maintenance purpose. In this mode, each conveyor or major component is operated from
push-button panels located in the field.
Most interlocks related to the equipment components are active; however interlocks between
equipment are not. The interlocks and permissive signals are described in detail later in this
document.
The conveyors must be stopped in order to switch to local mode. When switching to local
mode, the start/stop/jog/on/off selectors must not be active. If any command is active when
the LCS is switched an alarm is generated and the device will not start.
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3.3 Maintenance Mode
Maintenance mode is only for the conveyor drives. Each drive system has a local operator panel
which is used for detailed drive diagnostics and operation of the drive in a stand-alone
maintenance mode. This mode is will be used only for commissioning and drive
troubleshooting.
Maintenance mode can only be entered at the drive local operator panel and is interlocked by
the DCS, and only when the conveyors are stopped.
If PLC-DCS communications is lost, the PLC will allow maintenance mode without DCS
interlocking.
3.4 Warnings and Alarms
All equipment will have associated warnings and alarms. Warnings will not stop equipment
operation. Alarms will stop equipment depending on the operating mode and the interlocks.
Alarms generated from emergency devices (pull cords and e-stops) always stop equipment and
are hardwired independent of the PLC.
All warnings and alarms signals are always latched by the PLC. The signals may be used directly
or processed through a time delay or other logic to avoid fall trips.
Alarms and warnings must be reset by the DCS. If the signal that initiated the alarm is still
present, the alarm (or warning) will not be reset to avoid unnecessary re-triggering.
4 CVB-0001 operating philosophy
4.1 Reducer
The reducer has an oil circulation pump (0.75 kW motor, 230/460V, 3PH, 60Hz), and a heating
system consisting an immersion heater with integral thermostat control (2 kW heater, 480V,
3PH, 60Hz).
The reducer circulation pump runs whenever the conveyor drive is starting, running or stopping.
The reducer heating system operates whenever the circulation pump is running.
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The reducer is cooled by a fan mounted on the high speed shaft. When the oil temperature is
above the allowable operating temperature a warning is sent to the DCS. When the oil
temperature is too low a warning is sent to the DCS. The conveyer shall be shutdown if the
switch that has caused the warning to be issued is not reset within 15 minutes of the warning
being sent to the DCS. This signal is derived from temperature switch.
The oil heater runs whenever the oil temperature is low. This signal is derived from integral
thermostat of heater.
The reducer cannot be operated without the circulation pump if the input RPM will not be
maintained at 750 RPM or higher.
The speed reducer is also equipped with four vibration sensor mounted at each reduction stage
and at the input shaft, one oil level switch and one oil flow switch.
The vibration sensor will have two set points. The DCS will display a warning if the lower set
point is exceeded (XXX above nominal values measured during commissioning). The DCS will
shutdown the conveyor if the higher set point is exceeded (XXX above nominal values measured
during commissioning). The DCS will also display the current vibration level.
The DCS will shutdown the conveyor if a signal is received from the low oil level switch.
The DCS will shutdown the conveyor if a signal is received from the flow switch indicating that
the oil pump is not producing flow, if the motor is operating below 750 RPM.
4.2 Brake System
The brake system that is included with CVB-0001 is a thruster type brake and is only designed to
prevent the conveyor from rolling backwards when stopped; it shall not be used dynamically for
stopping the conveyor.
The thruster brake will be signaled to release the brake disc when the holding torque is
confirmed in the start sequence.
The thruster brake will be signaled to apply, or clamp the brake disc, when the conveyor speed
is at or below 3%, but prior to 0% to ensure no roll back.
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4.3 Drive motor
The conveyor VFD will be operated in “Speed Mode” and maintain the conveyor at constant
speed. The startup time of the conveyor is 30 seconds and will start using a startup ramp as
indicated below:
Time (seconds) Speed (%)

0 0
7.5 10
15 25
28 95
30 100
CVB-0001 Starting Ramp

120
100
Percent Speed
80
60
40
20
0
0 5 10 15 20 25 30 35 40
Time (seconds)
In most scenarios the conveyor will drift to a stop in less than 10 seconds. The stopping time will
be limited to 8 seconds for all non-emergency cases when using the drive for stopping. A nearly
linear ramp shall be used as indicated below:
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0 100
1.5 95
3 85
8 0
CVB-0001 Stopping Ramp

120
100
Percent Speed
80
60
40
20
0
0 2 4 6 8 10
Time (seconds)
The motor is equipped with an encoder and blower for cooling the motor when operating in
creep speed.
Below are basic descriptions of the starting and stopping processes the conveyor:
Starting process:
• Drive on
• Holding torque confirmed
• Brake released
• Startup ramp
Stopping process:
• Stopping ramp
• Zero speed confirmed
• Brake applied
• Drive off
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Emergency stop (hard wired from safety relay)
• Stopping ramp
• Brake applied
• Drive off (by safety relay timer)
Loss of power
• Brake applied
• Conveyor stops (time unknown)
• Conveyor inoperable
Loss of power during start-up and stopping
• Brake applied
The DCS will send a signal to reduce the load that is being put onto the conveyor if a signal is
received from the VFD indicating that the motor is 10% overloaded. A warning will also be
issued by the DCS for this condition.
The DCS will send a signal to stop loading the conveyor if a signal is received from the VFD
indicating that the motor is 10% overloaded for 100 seconds or more. A warning will also be
issued by the DCS for this condition. The DCS will shutdown the conveyor if the overload has
not been reduced within 50 seconds of receiving this warning.
4.4 Operating Speeds
In REMOTE-AUTO and REMOTE-MANUAL the sacrificial conveyor shall operate at constant

speed to maintain the conveyor at its design speed of 2.9 m/s.
In LOCAL mode, the conveyor will run at the normal speed (100%) and can also be operated at
creep speed (10%). Creep speed cannot be selected if the reducer oil circulation pump is
inoperable.
In MAINTENANCE mode (from the drive HMI) the drive can be run at variable speed for drive
testing purposes only.
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4.5 Pulleys
There are a total of five pulleys on Conveyor CVB-0001, one of which is driven by the 250kW
gearbox (head pulley). In addition to the drive pulley there is a tail pulley, a take-up pulley and
two bend pulleys. The drive pulley is equipped with one RTD in each bearing (two total for the
pulley).
Each of the RTD’s will have two set points. The DCS will display a warning if the lower set point
is exceeded (75°C). The DCS will shutdown the conveyor if the higher set point is exceeded
(85°C). The DCS will also display the current temperature.
4.6 Vertical Gravity Take-up
The vertical Gravity Take-up provides constant take-up tension during operation. There are
four limit switches on the take-up tower to provide warning and shutdown signals as needed.
High-High position on the tower prevents the counterweight from colliding with the tower
structure during high tension conditions. When this switch changes state the DCS must
shutdown the conveyor.
High / Initial position on the tower will advise the operator that the counterweight is located in
the highest possible initial position for normal operation. When this switch changes state the
DCS will display a warning.
Low position on the tower will advise the operator that the belt has been subjected to sufficient
permanent elongation that belt replacement is needed or that the counterweight must be
raised to the High / Initial position. When this switch changes state the DCS will display a
warning.
Low-Low position on the tower provides alarm shutdown due to low tension condition or belt
breakage and also prevents the counterweight from touching the ground level and removing the
pretension (take-up tension) from the conveyor. When this switch changes state the DCS must
shutdown the conveyor.
4.7 Metal Detector
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If the Metal Detector senses a metallic item a signal is sent to the Material Marking equipment,
which is located downstream from the Metal Detector, and paint is sprayed onto the material
on the belt in the approximate area where the item was detected. Reset of the Metal Detector
must be done locally after removal of the metallic item.
The DCS will shutdown the conveyor if a signal is received from the Metal Detector.
4.8 Belt Scale
The Belt Scale utilizes the output from a speed sensor located on the tail pulley and integrated
load cells to calculate the total amount of material that has travelled over it and the instant
capacity of the belt conveyor. Regular calibration of the scale is accomplished by manually
lowering a calibration chain onto the conveyor belt over the Belt Scale.
The DCS must display the total amount of material that has passed over it and also the instant
capacity reading. The DCS will shutdown the conveyor if a fault signal is sent from the Belt Scale.
The speed signal from the Belt Scale will also be sent to the DCS.
4.9 Belt Rip Detection System
There are three “Mechanical” Belt Rip Detection Switches on this conveyor. One of the Belt Rip
Detection Switches is located after the loading zone under the carrying strand; one of the Belt
Rip Detection Switches is connected to the garland type impact idlers; one of the Belt Rip
Detection Switches is at the head end under the return strand.
The DCS will shut down the conveyor if a signal is received from any of the “Mechanical” Belt Rip
Detection Switches.
4.10 Speed Sensor
The Speed Sensor is located on one of the two bend pulleys and will be used to control the belt
speed via the VFD. This speed sensor is also used for zero speed / under speed detection and
over speed detection.
The slip of the conveyor at the drive pulley will be monitored by comparing the speed of the
bend pulley with the speed sensor to the speed of the drive pulley (from the VFD). The actual
speed will be the speed reported by the VFD and the reference speed will be the speed being
monitored by the speed sensor. Slip will be monitored during starting, normal running and
normal stopping; slip will not be monitored during power outage stops.
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The DCS will shut down the conveyor if a signal is received from the encoder detecting zero
speed for 25 seconds or more during the conveyor start up sequence.
received from the encoder detecting 3% under speed (slip) for 10 seconds or more when the
conveyor has been confirmed running at the normal operating speed. A warning will also be
issued by the DCS for this condition.
The DCS will shut down the conveyor if a signal is received from the encoder detecting 5% under
speed (slip) for 20 seconds or more when the conveyor has been confirmed running at the
normal operating speed.
The DCS will shut down the conveyor if a signal is received from the encoder detecting 15% over
speed for 10 seconds or more when the conveyor has been confirmed running at the normal
operating speed.
The DCS will start-up the conveyor using the encoder as a speed reference.
4.11 Emergency Pull Cord Switches
The Emergency Pull Cord Switches provide an emergency shutdown signal when activated. They
are located along both sides of the conveyor.
The DCS will shut down the conveyor if a signal is received from any of the Emergency Pull Cord
Switches. All upstream equipment and the first piece of downstream equipment must be
stopped in conjunction with the activation of any of the Emergency Pull Cord Switches.
4.12 Belt Misalignment Switches
The Belt Misalignment Switches are two position switches. The first position will provide a
signal for a warning that the conveyor is slightly misaligned. The second position will send a
signal to the DCS to shutdown the conveyor for a major misalignment. Belt misalignment
switches are located on each side of the conveyor at the tail end before the loading zone (2
switches) and the head end before the discharge pulley (2 switches). There is a total of (4) Belt
Misalignment Switches on Conveyor CVB-0001.
The DCS will display a warning if a signal is received from any of the Belt Misalignment Switches
in the first position for slight misalignment.
The DCS will shut down the conveyor if a signal is received from any of the Belt Misalignment
Switches in the second position for major misalignment.
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4.13 Plugged Chute Switches
The Plugged Chute Switches provide shutdown signals in the event of a plugged head chute.
The discharge chute contains two microwave type plugged chute switches. If either switch or
both switches are tripped, the conveyor will shut down.
The DCS will shut down the conveyor if a signal is received from either of the microwave type
plugged chute switches.
4.14 Warning Horns and Strobe Lights
The Warning Horns and Strobe Lights are audible and visual warnings to personnel that the
conveyor is going to start. There is a 30 second delay of the start of the conveyor after the
Warning Horns and Strobe Lights are activated. This delay will allow for personnel in the area to
move to a safe distance from the conveyor.
The DCS will activate the Warning Horns and Strobe Lights when the permissive to start the
conveyor is given from the Master Control System (by others).
The DCS will keep the Strobe Lights activated until the conveyor has been confirmed running at
the normal operating speed.
4.15 Belt Tension Monitor
The Belt Tension Monitor measures tension at the high tension pulley to monitor pulley loads
and maximum belt tension. The torque output values from the VFD must be recorded and used
to calculate the effective tension at each drive pulley. The effective tensions will then be used
to calculate the maximum tension in the belt with the following equation:
T1MAX = [( 2*i ) /( DPull )]*( ΤPD ) + TTU
Where “i” is the reduction ratio (20.5:1), “DPull is the drive pulley diameter (0.952m), ΤPD is the
torque of the primary drive pulley (N-m), and TTU is the take-up tension (88,600 N). Please note
the exact counterweight value must be recorded during installation in order to know the actual
take-up tension of the conveyor.
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The DCS will send a signal to reduce the load that is being put onto the conveyor if the belt
tension reaches a value of 170,000 N. A warning will also be issued by the DCS for this
condition.
The DCS will send a signal to stop loading the conveyor if the belt tension reaches a value of
170,000 N for 20 seconds or more. A warning will also be issued by the DCS for this condition.
The DCS will shutdown the conveyor if the tension has not been reduced within 50 seconds of
receiving this warning.
4.16 Dust Control System (by Bechtel)
Control interface with dust collectors to be done by others. Permissive for conveyor to operate
may not be granted by the Master Control System if the dust control system is not functioning
properly.
5 CVB-002 Operating Philosophy
5.1 Brake System
Two brake systems are included with CVB-0002; both are spring applied and hydraulically
released (fail safe). One brake system will be installed at the tail end and will be used for
stopping during instances that electrical power is not available. The second brake system will be
installed at the head end and is only designed to prevent the conveyor from rolling backwards
when stopped. Each brake system consists of two brake discs with one caliper each. Both discs
are mounted to the tail pulley for the tail end system. The head end system has one disc
mounted on each drive pulley.
Both brake systems will be signaled to release the brake discs when the holding torque is
confirmed in the start sequence. This signal cannot be given if either brake controller reports a
system fault.
Both braking systems are equipped with their own digital controller and encoders to provide the
necessary speed signals. The speed signals from the brakes will be shared with the DCS via
Profibus communication. The brake controllers have their own dedicated uninterruptable
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power supply which enables each system to regulate the pressure in the hydraulic circuit with or
without electrical power.
For powered stops, both brake systems will be signaled to apply, or clamp the brake disc, when
the conveyor speed is at or below 3%, but prior to 0% to ensure no roll back.
The brake system at the tail end will apply full braking torque and follow a nearly linear stopping
ramp to stop the conveyor in 15 seconds during instances that electrical power is not available
for stopping. In these instances, the brake system at the head end will need to remain released
until the conveyor is at 3% speed. Pressure in the hydraulic circuits will be maintained using
accumulators.
The DCS will shutdown the conveyor if the brake controller reports a system fault during normal
operation.
Each brake system comes with a fully redundant hydraulic circuit and the DCS will alternate
which hydraulic pump is used to release the brakes by sending a signal indicating which pump
shall be used. The operator will also be able to manually override this command and select
either pump in case one pump requires maintenance.
Each brake system is equipped with a pressure differential switch for dirty filter indication, a
dual switch that monitors releasing/applying the brakes and also pad wear, a high temperature
switch and a low oil level switch.
The DCS will display if the brakes are applied or released. Each caliper (pad) has its own switch.
The DCS will display when the pads have worn sufficiently to require adjustment. Each caliper
(pad) has its own switch.
The DCS will display a warning if a signal is received from the pressure differential switch that
the filter is nearing replacement.
The DCS will display a warning if a signal is received from the high temperature switch.
The DCS will display a warning if a signal is received from the low oil switch.
5.2 Drives
The two 3,800 kW synchronous motors that are used to drive the Overland Conveyor 0220-CVB-
0002 are controlled using the Cycloconverters to operate with unequal load sharing. Unequal
load sharing is required in order to prevent full body belt slip at the secondary drive pulley. The
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load for normal running needs to be shared at a ratio of 60% on the primary drive pulley and
40% on the secondary drive pulley. The maximum allowable continuous power draw for either
of the drives is 4,370 kW.
The motors are equipped with a common cooling system for both motors. The cooling system
will be operating any time the drives are operating. The cooling system is equipped with
redundant pumps and fans to ensure that cooling will be available. The cooling system must be
operable in order to operate the conveyor. In the case that the cooling system reports a fault
during operation an alarm shutdown will be initiated by the DCS.
Each motor is equipped with (6) slot thermometer RTDs, (2) air inlet thermometer RTDs, (1) air
outlet thermometer RTD, (4) cooling fans, (1) speed encoder and (4) instruments that will
monitor the air gap between the rotor and the stator.
is exceeded (T+10°C). The DCS will shutdown the conveyor if the higher set point is exceeded
(T+10°C). “T” is the normal operation temperature of the motor, but the temperature should
not exceed 140°C before commissioning. The DCS will also display the current temperature.
Either temperature switch will initiate a conveyor shutdown when a change of state takes place.
One temperature switch is in the rotor and one temperature switch is in the stator.
An air gap of 8mm in between the rotor and stator is required for operation. A warning will be
issued by the DCS when the air gap is less than 7mm. An alarm shutdown will be issued by the
DCS when the air gap is less than 6.5mm. The DCS will also display the current air gap between
the rotor and stator.
The conveyor Cycloconverters will be operated in “Speed Mode” and will maintain the conveyor
at constant speed. The startup time of the conveyor is 360 seconds and will startup using an S-
curve ramp as indicated below:

0 0
0.5 0.2
21.6 10
108 10
144 17
324 93
360 100
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CVB-0002 Starting Ramp

120
100
Percent Speed
80
60
40
20
0
0 50 100 150 200 250 300 350 400
Time Seconds
The conveyor Cycloconverters will be used for stopping the conveyor for all planned stopping
situations, including emergency stops. In the case of a power outage the Cycloconverters will
not be available for ramping down the speed and the winch will lock the take-up carriage in
place and the tail end brake will be applied such that the conveyor will stop in approximately 15
seconds. A nearly linear ramp shall be used as indicated below for planned stops:

0 100
6.8 95
13.5 85
45 0
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CVB-0002 Stopping Ramp

120
100
Percent Speed
80
60
40
20
0
0 10 20 30 40 50
Time (seconds)
In the case that one of the motors is inoperable the procedure is as follows:
• Stop feed onto the conveyor

• Disable the bad drive
• Increase the take-up tension to 320kN using the winch
• Run the remaining drive at 10% speed to unload the conveyor (the drive can be run until
the thermal limit is reached and then must cool down to safe operating temperatures; )
• Repeat the steps of unloading at 10% speed until the thermal limit is reached followed by
a cool down period until the conveyor is empty
After Stop from normal Operation the motor can be operated with 200% overload for 2 minutes.
Afterwards a cool down phase of 9 minutes is obligatory. This can then be followed by 2 more
minutes with 200% overload period again. An overload period should not be started unless the
stator and rotor temperatures are less than 85°C.
Longer overload periods beginning from a lower temperature level do not have advantage. In
this case the cool down phase has to be increased due to the higher temperature range.
If the motor was powered above 100% load, a cool down phase has to follow before an overload
period can start.
If the emergency operation starts from nearly cold motor conditions, (stator and rotor < 50°C),
the overload period can be 6.5 minutes. Afterwards the motor can be operated as described
above after a 9 minute cool down phase.
During the cool down phase the motor cooling system must stay in operation.
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Once the conveyor is empty it can be operated at a reduced tonnage of 1800mtph with one
drive only (operating at 4,370 kW). The starting and stopping of the conveyor will be the same
for this reduced tonnage mode as for the normal operating mode.
Below are basic descriptions of the starting and stopping processes the conveyor
Starting process:
• Drives on
• Drive cooling system on
• Holding torque confirmed
• Brakes released
• Startup ramp
Stopping process:
• Stopping ramp
• Brakes applied
• Drives off
• Drive cooling system off
Emergency stop (hard wired from safety relay)
• Stopping ramp
• Brakes applied
• Drives off (by safety relay timer)
Loss of power
• Drives off
• Take-up carriage locked in place by winch brakes
• Tail brake applied
• Conveyor stops (approx. 15 seconds)
• Zero speed confirmed by brake controller
• Head brake applied
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Loss of power during start-up and stopping
• Drives off
• Take-up carriage locked in place by winch brakes
• Tail brake applied
• Zero speed confirmed by brake controller
• Head brake applied
Cycloconverter fault during operation
• To be treated as a loss of power stop
received from the Cycloconverter indicating that the motor is 10% overloaded. A warning will
also be issued by the DCS for this condition.
The DCS will send a signal to stop loading the conveyor if a signal is received from the
Cycloconverter indicating that the motor is 10% overloaded for 100 seconds or more. A warning
will also be issued by the DCS for this condition. The DCS will shutdown the conveyor if the
overload has not been reduced within 300 seconds of receiving this warning.
5.3 Operating Speeds
The following operating speeds shall be available for the overland conveyor:
Mode Full - 100% Reduced - Creep -

50% 10% (1)
Remote-Auto X X
Remote-Manual X X
Local X X
Maintenance X(2) X(2) X(2)
Table 2: Conveyor CVB-002 speeds
Notes: 1.Creep speed only allowed if conveyor is empty

2. Speed is variable and is set at drive panel in maintenance mode
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5.4 Pulleys
There are a total of twenty four pulleys on Conveyor CVB-0002, two of which are driven by the
two 3800kW Cycloconverter Speed Drives. In addition to the two drive pulleys there is a head
pulley, a high tension bend pulley, two low tension bend pulleys, a take-up pulley, a tail pulley,
eight horizontally mounted turn-over pulleys and eight vertical/45-degree mounted turn-over
support pulleys. The head pulley, high tension bend pulley, the two drive pulleys and the tail
pulley are equipped with one RTD in each bearing (two total for each pulley). The two drive
pulleys are also equipped one vibration sensor in each bearing (two total for each pulley).
is exceeded (75°C). The DCS will shutdown the conveyor if the higher set point is exceeded
(85°C). The DCS will also display the current temperature.
Each of the vibration sensors will have two set points. The DCS will display a warning if the
lower set point is exceeded (XXX above nominal values measured during commissioning). The
DCS will shutdown the conveyor if the higher set point is exceeded (XXX above nominal values
measured during commissioning). The DCS will also display the current vibration level.
5.5 Horizontal Winch Take-up
The conveyor take-up is managed by a vector controlled winch that is designed to maintain a
constant tension of 157 kN. During acceleration and deceleration the take-up pulley (carriage)
will move, due to the change of belt slack in the system. In these cases the winch will either pay
in (winch pulling cable onto winch drum) or pay out (conveyor pulling cable from the winch
drum). The winch is designed to pull with higher force for the acceleration and deceleration
cases to accommodate any difference in response time between the winch and conveyor. The
force with which the winch will pull will vary and will be whatever is required to maintain a line
speed between 0.10 and 0.20 meters per second.
In the case when one of the two synchronous motors is inoperable, the take-up winch will be
required to increase the take-up tension above 157 kN. When one drive is inoperable and the
conveyor is loaded with material, the take-up will go from being dynamic to being fixed and the
tension will be increased to 295 kN and held on the winch brake. The conveyor will be emptied
using the remaining drive with the increased take-up tension. When one drive is inoperable and
the conveyor is empty, the take-up will be dynamic and the tension will be maintained at 157
kN. In this case the conveyor will only be able to transport 1800 mtph for the highest friction
case and 2450 mtph for the lowest friction case.
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There are four limit switches on the take-up carriage runway to provide warning and shutdown
signals as needed.
Over travel position #1 on the carriage runway advises the operator that the carriage is not
positioned correctly and that it is encroaching on a collision. When this switch changes state the
DCS must issue an alarm. This condition occurs when tension of the conveyor is such that the
carriage movement will require the winch to pay out.
Over travel position #2 on the carriage runway prevents the carriage from colliding with the
conveyor structure. When this switch changes state the DCS must shutdown the conveyor. This
condition occurs when tension of the conveyor is such that the carriage movement will require
the winch to pay out or could occur due to the winch cables breaking.
End travel position on the carriage runway will advise the operator that the belt has been
subjected to sufficient permanent elongation that belt replacement is needed. When this
switch changes state the DCS will display an alarm.
Over travel position #3 on the carriage runway provides alarm shutdown due to low tension
condition or belt breakage and also prevents the carriage from colliding with the conveyor
structure. When this switch changes state the DCS must shutdown the conveyor.
5.6 Belt Rip Detection System
There is one “Electronic” Belt Rip Detection unit on this conveyor. The Belt Rip Detection unit is
located after the loading zone under the carrying strand. The unit comes with a transmitter,
receiver, speed sensor, and belt rip scanner central unit. The transmitter, receiver and speed
sensor are wired to the central unit for signal processing.
There are three “Mechanical” Belt Rip Detection Switches on this conveyor. One of the Belt Rip
Detection Switches is located after the loading zone under the carrying strand; one of the Belt
Rip Detection Switches is connected to the garland type impact idlers; one of the Belt Rip
Detection Switches is at the head end under the return strand.
The Belt Rip Detection unit will provide a “Ready” signal to the DCS. The conveyor cannot be
started if this signal is not received.
The DCS will display a warning if a “Pre-Warning Coil” signal is detected by the Belt Rip
Detection unit.
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The DCS will shutdown the conveyor if a “Belt Rip” signal is received from the Belt Rip Detection
unit.
The DCS will shut down the conveyor if a signal is received from any of the “Mechanical” Belt Rip
Detection Switches.
5.7 Speed Sensor
The Speed Sensors are encoders located on low tension bend pulleys (one pulley with two
encoders at the tail end and one pulley with two encoders at the head end). The Speed Sensor
at the tail end will be used for to provide a speed signal to the brake controller. The Speed
Sensor at the head end will be used for to provide a speed signal to the brake controller and will
also be used to control the belt speed via the Cycloconverter. These encoders are also used for
zero speed / under speed (slip) detection and over speed detection.
The slip of the conveyor at the secondary drive pulley will be monitored by comparing the speed
of the bend pulley with the speed sensor to the speed of the secondary drive pulley (from the
cycloconverter). The actual speed will be the speed reported by the cycloconverter and the
reference speed will be the speed being monitored by the speed sensor. Slip will be monitored
during starting, normal running and normal stopping; slip will not be monitored during power
outage stops.
The slip of the conveyor at the primary drive pulley is monitored by the gearless drive controller
by comparing the two speed signals from the two cycloconverters.
The DCS will shut down the conveyor if a signal is received from either encoder detecting zero
speed for 25 seconds or more during the conveyor start up sequence.
received from either encoder detecting 3% under speed (slip) for 10 seconds or more when the
conveyor has been confirmed running at the normal operating speed.
The DCS will shut down the conveyor if a signal is received from either encoder detecting 5%
under speed (slip) for 20 seconds or more when the conveyor has been confirmed running at
The DCS will shut down the conveyor if a signal is received from either encoder detecting 15%
over speed for 10 seconds or more when the conveyor has been confirmed running at the
normal operating speed.
The DCS will start-up the conveyor using the encoder at the head end as a speed reference.
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5.8 Emergency Pull Cord Switches
The Emergency Pull Cord Switches provide an emergency shutdown signal when activated. They
are located along both sides of the conveyor.
The DCS will shut down the conveyor if a signal is received from any of the Emergency Pull Cord
Switches. All upstream equipment and the first piece of downstream equipment must be
stopped in conjunction with the activation of any of the Emergency Pull Cord Switches.
5.9 Belt Misalignment Switches
The Belt Misalignment Switches are two position switches. The first position will provide a
signal for a warning that the conveyor is slightly misaligned. The second position will send a
signal to the DCS to shutdown the conveyor for a major misalignment. Belt misalignment
switches are located on each side of the conveyor at the tail end before the loading zone (2
switches), at the tail end before the take-up pulley (2 switches), the head end before the
discharge pulley (2 switches), the head end before the secondary drive pulley (2 switches), the
head end after the turn-over (2 switches) and at the beginning, the middle and the end of the
horizontal curve on the carry and return belt (12 switches), There is a total of (22) Belt
Misalignment Switches on Conveyor CVB-0002.
The DCS will display a warning if a signal is received from any of the Belt Misalignment Switches
in the first position for slight misalignment.
The DCS will shut down the conveyor if a signal is received from any of the Belt Misalignment
Switches in the second position for major misalignment.
5.10 Stock Pile Level Switches
The conveyor will have two ultrasonic stock pile level indicator switches at the discharge pulley.
One will be used for level indication and one will be used for emergency stop. The level
indicator switches will act independently and use distinct wave ranges.
The DCS will display the stock pile level with the signal from one of the level indicator switches
and will send alarms when the stock pile is nearing its maximum level.
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The DCS will shut down the conveyor if a signal is received from the emergency stop pile level
indicator.
5.11 Warning Horns and Strobe Lights
The Warning Horns and Strobe Lights are audible and visual warnings to personnel that the
conveyor is going to start. There is a 30 second delay of the start of the conveyor after the
Warning Horns and Strobe Lights are activated. This delay will allow for personnel in the area to
move to a safe distance from the conveyor.
The DCS will activate the Warning Horns and Strobe Lights when the permissive to start the
conveyor is given from the Master Control System (by others).
The DCS will keep the Strobe Lights activated until the conveyor has been confirmed running at
5.12 Belt Tension Monitor
The Belt Tension Monitor measures tension at the high tension pulley to monitor pulley loads
and maximum belt tension. The torque output values from the VFD must be recorded and used
to calculate the effective tension at each drive pulley. The effective tensions will then be used
to calculate the maximum tension in the belt with the following equation:
T1MAX = [( 2*i ) /( DPull )]*( ΤPD + ΤSD ) + TTU
Where “i” is the reduction ratio (1:1 for the gearless drive), “DPull is the drive pulley diameter
(1.880m), ΤPD is the torque of the primary drive pulley (N-m), ΤSD is the torque of the secondary
drive pulley (N-m), and TTU is the take-up tension (157,000 N). The value of the take-up tension
can be set as constant or can be reported from the take-up winch.
The DCS will send a signal to reduce the load that is being put onto the conveyor if the belt
tension reaches a value of 1,420,000 N. A warning will also be issued by the DCS for this
condition.
The DCS will send a signal to stop loading the conveyor if the belt tension reaches a value of
1,420,000 N for 20 seconds or more. A warning will also be issued by the DCS for this condition.
The DCS will shutdown the conveyor if the tension has not been reduced within 300 seconds of
receiving this warning.
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5.13 Dust Control System (by Bechtel)
Control interface with dust collectors to be done by others. Permissive for conveyor to operate
may not be granted by the Master Control System if the dust control system is not functioning
properly.
6 Interlocks and Permissives
Permissives are defined as signals which are local to the equipment and must be in the correct
state for the equipment to operate. Different sets of permissives may apply in different modes.
Interlocks are defined as signals from other devices or equipment which must be in the correct
state for the equipment to run. When one or more interlocks are present, the equipment is
“Interlocked”. Different sets of interlocks may apply in different modes.
When all permissives and interlocks are in the correct state, the equipment is “Ready to start”.
6.1 Conveyor CVB-001
The following table below shows the permissives for conveyor CVB-001. S indicates permissive
required to start; R indicates permissive required during running.
Permissive Operating Mode

Remote- Remote- Local Maint.
AUTO MANUAL
All device LCSs in AUTO S,R S,R
Pull cords S,R S,R S,R S,R
Brake not released R R R
Belt misalignment (2nd position – trip) S R
Under speed R R
Belt rip S,R S,R
Belt rip detector system fault (1) S,R S,R
Metal present on belt S,R S,R
Metal detector system fault (1) S,R S,R
Belt scale fault S,R S,R
Winch take-up high-high S,R S,R S,R
Winch take-up low-low S,R S,R S,R
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Drive VFD Fault S,R S,R S,R S,R

Drive pulley temperature high-high S,R S,R S,R
Drive motor blower not running S,R S,R S,R
Reducer oil pump not running S,R S,R S,R
Reducer vibration high-high S,R S,R S,R
Reducer temperature high-high S,R S,R S,R
Reducer oil temperature high-high S,R S,R S,R
Table 3: CVB-001 Permissives
Note 1: Detectors can be bypassed by DCS
The table below shows the interlocks for conveyor CVB-001. S indicates permissive required to
start; R indicates permissive required during running.
Interlocks Operating Mode

AUTO MANUAL
Plugged chute S,R S,R
CVB-002 not running S,R S,R
Table 4: CVB-001 Interlocks
The table below shows the permissives for conveyor CVB-002. S indicates permissive required
to start; R indicates permissive required during running.
Permissive Operating Mode

AUTO MANUAL
All device LCSs in AUTO S,R S,R
Pull cords S,R S,R S,R S,R
Brakes not released R R R
Belt misalignment (2nd position – trip) S R
Under speed R R
Belt rip S,R S,R
Belt rip detector system fault (1) S,R S,R
Belt tension high-high S,R S,R S,R
Belt tension low-low S,R S,R S,R
Winch VFD fault S,R S,R
Drive VFD Fault S,R S,R S,R S,R
Drive pulley vibration high-high S,R S,R S,R
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Drive pulley temperature high-high S,R S,R S,R

Drive motor cooling system fault S,R S,R S,R
Conveyor pulley vibration high-high S,R S,R S,R
Conveyor pulley temperature high-high S,R S,R S,R
Table 5: CVB-002 Permissives
Note 1: Detectors can be bypassed by DCS
The table below shows the interlocks for conveyor CVB-002. S indicates permissive required to
start; R indicates permissive required during running.
Interlocks Operating Mode

AUTO MANUAL
Stock pile level high-high S,R S,R
Table 6: CVB-002 Interlocks
7 Warnings and Alarms
Warnings and alarms can be produces either directly based on field based signals or internally
generated based on logic processing in the PLC. The following sections show all warnings and
alarms.
The following table shows warnings for CVB-001 based on instrumentation.
TAG DESCRIPTION
ZAH00513A1 0220-CVB-0001 BELT ALIGNMENT TAIL LEFT
ZAH00513B1 0220-CVB-0001 BELT ALIGNMENT TAIL RIGHT
ZAH00513A2 0220-CVB-0001 BELT ALIGNMENT HEAD LEFT
ZAH00513B2 0220-CVB-0001 BELT ALIGNMENT HEAD RIGHT
ZAH00515 0220-CVB-0001 TAKE UP HIGH
ZAL00515 0220-CVB-0001 TAKE UP LOW
TAL00527 0220-CVB-0001 REDUCER OIL TEMPERATURE LOW
TAH00527 0220-CVB-0001 REDUCER OIL TEMPERATURE HIGH
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TAH00525B 0220-CVB-0001 REDUCER TEMPERATURE HIGH (RTD#1)

TAH00525A 0220-CVB-0001 REDUCER TEMPERATURE HIGH (RTD#2)
VAH00525C 0220-CVB-0001 REDUCER VIBRATION HIGH STAGE #1
VAH00525B 0220-CVB-0001 REDUCER VIBRATION HIGH STAGE #2
VAH00525A 0220-CVB-0001 REDUCER VIBRATION HIGH STAGE #3
TAH00523B 0220-CVB-0001 DRIVE PULLEY TEMPERATURE HIGH (RTD#1)
TAH00523A 0220-CVB-0001 DRIVE PULLEY TEMPERATURE HIGH (RTD#2)
XA0533C 0220-CVB-0002 BELT RIP DETECTTOR SYSTEM FAILED
Table 7: CVB-001 Warnings
The following table shows the alarms for CVB-001 based on instrumentation.
TAG DESCRIPTION
HA00512A1 CVB-0001 PULL CORD LEFT
HA00512B1 CVB-0001 PULL CORD RIGHT
HS00532D CVB-0001 STOP LCS
HS00532E CVB-0001 EMERGENCY STOP LCS
SAL00510 CVB-0001 UNDER SPEED
ZAHH00513A1 CVB-0001 BELT ALIGNMENT TAIL LEFT
ZAHH00513B1 CVB-0001 BELT ALIGNMENT TAIL END RIGHT
ZAHH00513A2 CVB-0001 BELT ALIGNMENT HEAD LEFT
ZAHH00513B2 CVB-0001 BELT ALIGNMENT HEAD RIGHT
XA00514A1 CVB-0001 BELT RIP AT TAIL END LEFT
XA00514B1 CVB-0001 BELT RIP AT TAIL END RIGHT
XA00514A2 CVB-0001 BELT RIP AT HEAD END LEFT
XA00514B2 CVB-0001 BELT RIP AT HEAD END RIGHT
XA00533D CVB-0001 BELT RIP AT TAIL END (DETECTOR SYSTEM)
XA00514A CVB-0001 METAL DETECTED ON BELT
ZAHH00515 CVB-0001 TAKE UP HIGH HIGH
ZALL00515 CVB-0001 TAKE UP LOW LOW
LAH00516A CVB-0001 PLUGGED CHUTE (TOP)
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LAH00516B CVB-0001 PLUGGED CHUTE (BOTTOM)

TA00529 CVB-0001 DRIVE VFD ALARM
SCA00529 CVB-0001 DRIVE VFD FAULT
IAH01101 CVB-0001 MOTOR BLOWER OVERLOAD
IAH01105 CVB-0001 THRUSTER BRAKE OVERLOAD
IAH01102 CVB-0001 REDUCER COOLING FAN OVERLOAD
IAH01104 CVB-0001 REDUCER COOLING PUMP OVERLOAD
IAH01103 CVB-0001 REDUCER CIRCULATION PUMP OVERLOAD
FAL00521 CVB-0001 REDUCER OIL FLOW LOW
LAL00526 CVB-0001 REDUCER OIL LEVEL LOW
TAHH00525B CVB-0001 REDUCER TEMPERATURE HIGH (RTD#1)
TAHH00525A CVB-0001 REDUCER TEMPERATURE HIGH (RTD#2)
VAHH00525C CVB-0001 REDUCER VIBRATION HIGH STAGE #1
VAHH00525B CVB-0001 REDUCER VIBRATION HIGH STAGE #2
VAHH00525A CVB-0001 REDUCER VIBRATION HIGH STAGE #3
TAHH00523B CVB-0001 DRIVE PULLEY TEMPERATURE HIGH (RTD#1)
TAHH00523A CVB-0001 DRIVE PULLEY TEMPERATURE HIGH (RTD#2)
Table 8: CVB-001 Alarms
The following table shows the alarms for CVB-001 internally generated by the PLC.
TAG DESCRIPTION
CVB-001 DRIVE FAILED TO START
CVB-001 MOTOR BLOWER FAILED TO START
CVB-001 REDUCER COOLING FAN FAILED TO START
CVB-001 REDUCER CIRCULATION PUMP FAILED TO START
CVB-001 CONVEYOR UNDERSPEED
CVB-001 BELT OVERLOADED
Table 9: CVB-001 Alarms - Generated
The following table shows the warnings for CVB-002.
ZAH00542A1 CVB-0002 BELT ALIGNMENT TAIL END LEFT

ZAH00542B1 CVB-0002 BELT ALIGNMENT TAIL END RIGHT
ZAH00542A2 CVB-0002 BELT ALIGNMENT BEFORE DRIVE STATION LEFT
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ZAH00542B2 CVB-0002 BELT ALIGNMENT BEGINNING OF CURVE RIGHT

ZAH00542A3 CVB-0002 BELT ALIGNMENT BEGINNING OF CURVE LEFT
ZAH00542B3 CVB-0002 BELT ALIGNMENT BEGINNING OF CURVE RIGHT
ZAH00542A4 CVB-0002 BELT ALIGNMENT MIDDLE OF CURVE LEFT
ZAH00542B4 CVB-0002 BELT ALIGNMENT MIDDLE OF CURVE RIGHT
ZAH00542A5 CVB-0002 BELT ALIGNMENT MIDDLE OF CURVE LEFT
ZAH00542B5 CVB-0002 BELT ALIGNMENT MIDDLE OF CURVE RIGHT
ZAH00542A6 CVB-0002 BELT ALIGNMENT END OF CURVE LEFT
ZAH00542B6 CVB-0002 BELT ALIGNMENT END OF CURVE RIGHT
ZAH00542A7 CVB-0002 BELT ALIGNMENT END OF CURVE LEFT
ZAH00542B7 CVB-0002 BELT ALIGNMENT END OF CURVE RIGHT
ZAH00542A8 CVB-0002 BELT ALIGNMENT AT DRIVE STATION LEFT
ZAH00542B8 CVB-0002 BELT ALIGNMENT AT DRIVE STATION RIGHT
ZAH00542A9 CVB-0002 BELT ALIGNMENT AT DRIVE STATION LEFT
ZAH00542B9 CVB-0002 BELT ALIGNMENT AT DRIVE STATION RIGHT
ZAH00542A10 CVB-0002 BELT ALIGNMENT BEFORE DRIVE STATION LEFT
ZAH00542B10 CVB-0002 BELT ALIGNMENT BEFORE DRIVE STATION RIGHT
ZAH00542A11 CVB-0002 BELT ALIGNMENT AT HEAD END LEFT
ZAH00542B11 CVB-0002 BELT ALIGNMENT AT HEAD END RIGHT
XAL00548 CVB-0002 BELT RIP DETECTTOR SYSTEM FAILED
TAH00546A CVB-0002 HEAD END PULLEY TEMPERATURE HIGH RTD #1
TAH00546B CVB-0002 HEAD END PULLEY TEMPERATURE HIGH RTD #2
TAH00551A CVB-0002 SECONDARY DRIVE PULLEY TEMPERATURE HIGH RTD #1
TAH00551A CVB-0002 SECONDARY DRIVE PULLEY TEMPERATURE HIGH RTD #2
TAH00555A CVB-0002 PRIMARY DRIVE PULLEY TEMPERATURE HIGH RTD #1
TAH00555A CVB-0002 PRIMARY DRIVE PULLEY TEMPERATURE HIGH RTD #2
TAH00554A CVB-0002 RETURN PULLEY TEMPERATURE HIGH RTD #1
TAH00554A CVB-0002 RETURN PULLEY TEMPERATURE HIGH RTD #2
TAH00560A CVB-0002 TAIL PULLEY TEMPERATURE HIGH RTD #1
TAH00560B CVB-0002 TAIL PULLEY TEMPERATURE HIGH RTD #1
TAH00566 CVB-0002 PRIMARY DRIVE PULLEY TEMPERATURE HIGH RTD #1
TAH00569 CVB-0002 PRIMARY DRIVE PULLEY TEMPERATURE HIGH RTD #2
TAH00589 CVB-0002 SECONDARY DRIVE PULLEY TEMPERATURE HIGH RTD #1
TAH00592 CVB-0002 SECONDARY DRIVE PULLEY TEMPERATURE HIGH RTD #2
Table 10: CVB-002 Warnings
The following table shows the alarms for CVB-002.
HS00544A01-64 CVB-0002 PULLCORD LEFT
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HS00544B01-64 CVB-0002 PULLCORD RIGHT

ZAHH00542A1 CVB-0002 BELT ALIGNMENT SWITCH TAIL END LEFT
ZAHH00542B1 CVB-0002 BELT ALIGNMENT SWITCH TAIL END RIGHT
ZAHH00542A2 CVB-0002 BELT ALIGNMENT SWITCH BEFORE DRIVE STATION LEFT
ZAHH00542B2 CVB-0002 BELT ALIGNMENT SWITCH BEGINNING OF CURVE RIGHT
ZAHH00542A3 CVB-0002 BELT ALIGNMENT SWITCH BEGINNING OF CURVE LEFT
ZAHH00542B3 CVB-0002 BELT ALIGNMENT SWITCH BEGINNING OF CURVE RIGHT
ZAHH00542A4 CVB-0002 BELT ALIGNMENT SWITCH MIDDLE OF CURVE LEFT
ZAHH00542B4 CVB-0002 BELT ALIGNMENT SWITCH MIDDLE OF CURVE RIGHT
ZAHH00542A5 CVB-0002 BELT ALIGNMENT SWITCH MIDDLE OF CURVE LEFT
ZAHH00542B5 CVB-0002 BELT ALIGNMENT SWITCH MIDDLE OF CURVE RIGHT
ZAHH00542A6 CVB-0002 BELT ALIGNMENT SWITCH END OF CURVE LEFT
ZAHH00542B6 CVB-0002 BELT ALIGNMENT SWITCH END OF CURVE RIGHT
ZAHH00542A7 CVB-0002 BELT ALIGNMENT SWITCH END OF CURVE LEFT
ZAHH00542B7 CVB-0002 BELT ALIGNMENT SWITCH END OF CURVE RIGHT
ZAHH00542A8 CVB-0002 BELT ALIGNMENT SWITCH AT DRIVE STATION LEFT
ZAHH00542B8 CVB-0002 BELT ALIGNMENT SWITCH AT DRIVE STATION RIGHT
ZAHH00542A9 CVB-0002 BELT ALIGNMENT SWITCH AT DRIVE STATION LEFT
ZAHH00542B9 CVB-0002 BELT ALIGNMENT SWITCH AT DRIVE STATION RIGHT
ZAHH00542A10 CVB-0002 BELT ALIGNMENT SWITCH BEFORE DRIVE STATION LEFT
ZAHH00542B10 CVB-0002 BELT ALIGNMENT SWITCH BEFORE DRIVE STATION RIGHT
ZAHH00542A11 CVB-0002 BELT ALIGNMENT SWITCH AT HEAD END LEFT
ZAHH00542B11 CVB-0002 BELT ALIGNMENT SWITCH AT HEAD END RIGHT
SAL00543 CVB-0002 CONVEYOR UNDERSPEED
HS00575 CVB-0002 STOP PUSHBUTTON AT TAIL END
HS00575E CVB-0002 E-STOP PUSHBUTTON AT TAIL LCS
HS00573 CVB-0002 STOP PUSHBUTTON AT PRIMARY DRIVE LCS
HS00573E CVB-0002 E-STOP PUSHBUTTON AT PRIMARY DRIVE LCS
HS00576 CVB-0002 STOP PUSHBUTTON AT SECONDARY DRIVE LCS
HS00576E CVB-0002 E-STOP PUSHBUTTON AT SECONDARY DRIVE LCS
XA00548 CVB-0002 BELT RIP AT TAIL END (DETECTOR SYSTEM)
XS00543A1 CVB-0002 BELT RIP AT TAIL END
XA00543A2 CVB-0002 BELT RIP AT TAIL END
XS00543A3 CVB-0002 BELT RIP BY DRIVE STATION
XS00543A4 CVB-0002 BELT RIP AT HEAD END
XA00543A5 CVB-0002 BELT RIP AT HEAD END
TAHH00566 CVB-0002 PRIMARY DRIVE PULLEY TEMPERATURE HIGH RTD #1
TAHH00569 CVB-0002 PRIMARY DRIVE PULLEY TEMPERATURE HIGH RTD #2
TAHH00589 CVB-0002 SECONDARY DRIVE PULLEY TEMPERATURE HIGH RTD #1
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TAHH00592 CVB-0002 SECONDARY DRIVE PULLEY TEMPERATURE HIGH RTD #2

VAHH00567 CVB-0002 PRIMARY DRIVE PULLEY VIBRATION HIGH SENSOR #1
VAHH00568 CVB-0002 PRIMARY DRIVE PULLEY VIBRATION HIGH SENSOR #2
VAHH00590 CVB-0002 SECONDARY DRIVE PULLEY VIBRATION HIGH SENSOR #1
VAHH00591 CVB-0002 SECONDARY DRIVE PULLEY VIBRATION HIGH SENSOR #2
VAHH00522A CVB-0002 SECONDARY DRIVE PULLEY VIBRATION HIGH SENSOR #1
VAHH00522B CVB-0002 SECONDARY DRIVE PULLEY VIBRATION HIGH SENSOR #2
VAHH00553A CVB-0002 PRIMARY DRIVE PULLEY VIBRATION HIGH SENSOR #1
VAHH00553B CVB-0002 PRIMARY DRIVE PULLEY VIBRATION HIGH SENSOR #2
Table 11: CVB-002 Alarms
The following table shows the alarms for CVB-002 internally generated by the PLC.
TAG DESCRIPTION
CVB-002 DRIVE FAILED TO START
CVB-002 CONVEYOR UNDERSPEED
STOCK PILE LEVEL HIGH
Table 12: CVB-002 Alarms - Generated
7.3 CVB-002 Winch
The following table shows the warnings for the winch system on CVB-002.
TAG DESCRIPTION
SCA00563 VFD ALARM
ZSL00547 TAKE-UP WINCH END OF TRAVEL LOW
ZSH00547 TAKE-UP WINCH END OF TRAVEL HIGH
Table 13: CVB-002 Winch Warnings
The following table shows the alarms for the winch system on CVB-002.
TAG DESCRIPTION
TA00563 VFD FAULT
ZSLL00547 TAKE-UP WINCH OVER TRAVEL LOW
ZSHH00547 TAKE-UP WINCH OVER TRAVEL HIGH
Table 14:CVB-002 Winch Alarms
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The following table shows the alarms for the winch on CVB-002 internally generated by the PLC.
TAG DESCRIPTION
BELT TENSION LOW
BELT TENSION HIGH
Table 15:CVB-002 Winch Alarms - Generated
7.4 Power Monitoring
The following table shows the warnings for the power monitoring system.
LSL00570 TRANSFORMER CVB-002-XFC1 OIL LEVEL LOW

PSH00570 TRANSFORMER CVB-002-XFC1 RAPID RISE
PSL00570 TRANSFORMER CVB-002-XFC1 OIL PRESSURE LOW
TSH00570 TRANSFORMER CVB-002-XFC1 OIL TEMPERATURE HIGH
LSL00571 TRANSFORMER CVB-002-XFC2 OIL LEVEL SWITCH LOW
PSH00577 TRANSFORMER CVB-002-XFC4 RAPID RISE RELAY
LSL00580 TRANSFORMER XFP-002 OIL LEVEL LOW
PSH00580 TRANSFORMER XFP-002 RAPID RISE RELAY
PSL00580 TRANSFORMER XFP-002 OIL PRESSURE LOW
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TSH00580 TRANSFORMER XFP-002 OIL TEMPERATURE HIGH

Table 16: Power monitoring warnings
The following table shows the alarms for the power monitoring system.
LSLL00570 TRANSFORMER CVB-002-XFC1 OIL LEVEL LOW

TSHH00570 TRANSFORMER CVB-002-XFC1 OIL TEMPERATURE HIGH
TSHH00572 TRANSFORMER CVB-002-XFC3 OIL TEMPERATUREHIGH
LSLL00580 TRANSFORMER XFP-002 OIL LEVEL LOW
TSHH00580 TRANSFORMER XFP-002 OIL TEMPERATURE HIGH
Table 17: Power monitoring alarms
7.5 Fire Alarms
Three fire alarms are located t in the e-houses.
XS00597 FIRE ALARM TBD

Table 18: Fire alarms
8 Data Interfaces
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The main PLC will interface to several other systems via communications networks. This section
describes the data interface with these various systems.
8.1 CVB-001 Drive VFD

The main PLC will communicate with the drive via Profibus. The following tables show the
commands and status signals between the PLC and the VFD.
From PLC to VFD: Commands

PLC Tag Name Data Description
Type
ON BOOL 1=DRIVE ON
START BOOL 1=DRIVE START
STOP BOOL 0=DRIVE NORMAL STOP, Maintained
RESET BOOL 1=FAULT RESET, Momentary 0->1 RESET
MAINT BOOL 1=MAINTENANCE MODE DISABLED, Maintained
SPEED INT SPEED COMMAND -16324 to +16324,-100% to +100%
Table 19: CVB-001 PLC to VFD commands
From VFD to PLC: Status

Type
READY BOOL 1=DRIVE READY, Maintained
RUNNING BOOL 1=DRIVE RUNNING, Maintained
ACCEL BOOL 1=DRIVE ACCELERATING, Maintained
DECEL BOOL 1=DRIVE DECELERATING, Maintained
AT SPEED BOOL 1=DRIVE AT COMMANDED SPEED, Maintained
MAINT BOOL 1=DRIVE IN MAINTENANCE MODE, Maintained
FAULT BOOL 1=DRIVE FAULT, Maintained
SPEED INT ACTUAL SPEED -16384 to + 16384, -100% to +100%
TORQ INT TORQUE 0 to 16324, 0 to TBD Nm
MBT-1 INT MOTOR BEARING 1 TEMP 0 to 16384, 0 to TBD oC
MBT-2 INT MOTOR BEARING 2 TEMP 0 to 16384, 0 to TBD oC
MWT1-1 INT MOTOR WINDING 1-1 TEMP 0 to 16384, 0 to TBD oC
Table 20: CVB-001 VFD to PLC status
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8.1.1 Communication loss
The drive will automatically detect communication loss with the PLC. If communication is lost
the drive will set all the command signals to 0 which will initiate a NORMAL STOP.
When communications are lost, it will be possible to enter MAINTENANCE mode at the drive.
8.1.2 Emergency Stop
Any pull cord or emergency stop button will result in a hardwired trip of the safety relay. The
safety relay output is wired direct to the drive, wired fail-safe (closed contact = relay ok).
On loss of the signal, the drive will initiate a FAST STOP regardless of the command signals from
the PLC. When the conveyor is stopped the drive will disable the output power stage.
8.2 CVB-002 Drive Controller

The main PLC will communicate with the drive controller via Profibus. The following tables show
the commands and status signals between the PLC and the driver controller.

Type
ON BOOL 1=DRIVE ON
MAINT_1 BOOL 1=MOTOR 1 MAINTENANCE MODE DISABLED, Maintained
MAINT_2 BOOL 1=MOTOR 2 MAINTENANCE MODE DISABLED, Maintained
DISABLE_1 BOOL 1=MOTOR 1 DISABLE, Maintained
DISABLE_2 BOOL 1=MOTOR 2 DISABLE, Maintained
Table 21: CVB-002 PLC to VFD commands
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Type
ACCEL BOOL 1=DRIVE ACCELERATING, Maintained
DECEL BOOL 1=DRIVE DECELERATING, Maintained
AT SPEED BOOL 1=DRIVE AT COMMANDED SPEED, Maintained
MAINT BOOL 1=DRIVE IN MAINTENANCE MODE, Maintained
DISABLE_1 BOOL 1=MOTOR 1 DISABLED, Maintained
DISABLE_2 BOOL 1=MOTOR 1 DISABLED, Maintained
M1-AIT-1 INT MOTOR 1 AIR INLET 1 TEMP 0 to 16384, 0 to TBD oC
M1-AOT-2 INT MOTOR 1 AIR OUTLET 2 TEMP 0 to 16384, 0 to TBD oC
M1-WT1-1 INT MOTOR 1 WINDING 1-1 TEMP 0 to 16384, 0 to TBD oC
M2-AOT-2 INT MOTOR 2 AIR OUTLET 2 TEMP 0 to 16384, 0 to TBD oC
Table 22: CVB-002 VFD to PLC status
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8.2.2 Emergency Stop
Any pull cord or emergency stop button will result in a hardwired trip of the safety relay. The
safety relay output is wired direct to the drives controller, wired fail-safe (closed contact = relay
ok).
On loss of the signal, the drive controller will initiate a FAST STOP regardless of the command
signals from the PLC. When the conveyor is stopped the controller will disable the output power
stages.
8.3 CVB-002 Winch VFD
The main PLC will communicate with the winch VFD via Profibus. The following tables show the
commands and status signals between the PLC and the VFD.

Type
ON BOOL 1=DRIVE ON
Table 23: CVB-002 Winch PLC to VFD commands

Type
Table 24:CVB-002 Winch VFD to PLC status
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8.4 CVB-002 Brakes Controller
TBD
8.5 Pull cord controller
The pull cord controller system comprises of a monitoring and control system for the overland
conveyor 0220-CVB-0002. This system is provided by Austdac LTD of Australia.
This system provides the control, monitoring and pre start alarm for the overland conveyor
0220-CVB-0002.
This system consists of the following major items:
- Conveyor Control Panel

- Conveyor Station c/w pull-cord switch, horn and strobe light
- Conveyor Station c/w pull-cord switch
- Tail End Unit
- Belt Wander Stations with belt alignment switch
8.5.1 Conveyor Control Panel

The overland conveyor 0220-CVB-0002 has a main control panel which provides the
emergency stop control circuit interface to the drives motors control circuit. The panel also
provides a visual interface via its local HMI and a communication gateway into the PLC
systems via Profibus-DP.
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Control Narrative
8.5.2 Conveyor Station c/w pull-cord switch, horn and strobe light
The overland conveyor 0220-CVB-0002 is fitted with conveyor stations that come complete
with a pull-cord switch for stopping the conveyor via the pull-cord cable, and strobe light &
horn for visual and audible pre-start warning prior to the conveyor starting.
In the event that the pull-cord switch is tripped it provides a location of the trip back
through the Profibus.
8.5.3 Conveyor Station c/w pull-cord switch

The overland conveyor 0220-CVB-0002 is fitted with conveyor stations that come complete
with a pull-cord switch for stopping the conveyor via the pull-cord cable.
In the event that the pull-cord switch is tripped it provides a location of the trip back
through the Profibus.
8.5.4 Conveyor Tail End Unit

The tail end of overland conveyor 0220-CVB-0002 has a tail end unit that provides cable
integrity monitoring through the length of the conveyor. It also provides part of the
emergency stop system for the conveyor via the end of line transmitters.
8.5.5 Belt Wander Stations

The overland conveyor 0220-CVB-0002 is fitted with belt wander marshaling enclosures
along the conveyor. These enclosures are used for the interface between the physical switch
field limit switch and the Dupline system.
8.6 Belt scale
The main PLC will communicate with the belt scale via Profibus. The following tables show the
commands and status signals between the PLC and scale.
From PLC to Scale: Commands

Type
R-TOTAL BOOL 1=RESET TOTAL TONNAGE , Momentary, 0->1 RESET
R-FAULT BOOL 1=RESET FAULTS, Momentary, 0->1 RESET
Table 25: CVB-001 PLC to Belt scale commands
Rev B 18-Mar-11
Page 83 of 180
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From Scale to PLC: Status

Type
FAULT BOOL 1=SCALE FAULT, Maintained
TPH REAL TONS PER HOUR
TOTAL REAL TOTAL TONNAGE
SPEED REAL BELT SPEED m/s
Table 26: CVB-001 Belt scale to PLC status
8.7 Power Monitoring
A power meter will be installed to monitor the 480V feeders. The following status information
will be provided by the power meter.
From Power meter to PLC: Status

Type
A – VOLTS REAL PHASE A VOLTAGE
B – VOLTS REAL PHASE B VOLTAGE
C - VOLTS REAL PHASE C VOLTAGE
A - AMPS REAL PHASE A CURRENT
B - AMPS REAL PHASE B CURRENT
C - AMPS REAL PHASE C CURRENT
AVG-PWR REAL AVERAGE POWER
Table 27: Power meter to PLC status
8.8 Miscellaneous devices
The PLC will interface with the blowers, pumps, heaters and fans on for CVB-001 via Profibus.
Each MCC location will have a Siemens Simocode C starters. The following commands and
status will be transferred between the PLC and the Simcodes.
From PLC to Simocode: Commands

Type
START BOOL 1=START, 0=NO START
Rev B 18-Mar-11
Page 84 of 180
Conveying System
Control Narrative
STOP BOOL 0=STOP, 1= NO STOP

Table 28: PLC to Simocode commands
From Simocode to PLC: Status

Type
RUN BOOL 1=RUNNING
OVLD REAL 1=OVERLOAD
Table 29: Simocode to PLC status
8.9 DCS
8.9.1 Communications configuration
The DCS will communicate with the PLC via Ethernet. The commands and status will be located
in the PLC in data tables DB1000 (commands) and DB1001 (status).
The data will be transferred using S7 READ and WRITE SFCs. The SFCs will be call via a cyclic OB
with an update time of 500ms.
DCS commands to the PLC will be maintained or momentary, depending on the command.
Momentary commands should be maintained for a minimum duration of 1 second to allow for
communication delays and PLC scan time.
8.9.2 Data tables
The following table shows the DCS to PLC commands.
DB Bit Description Values

Offset No.
0 COMMUNICATIONS HEARTBEAT 0-65535, COUNT UP
2 0 CVB-001 CONVEYOR LCS INTERLOCK 1=REMOTE, 0=LOCAL
1 CVB-001 MOTOR BLOWER LCS INTERLOCK 1=REMOTE, 0=LOCAL
2 CVB-001 THRUSTER BRAKE LCS INTERLOCK 1=REMOTE, 0=LOCAL
3 CVB-001 REDUCER COOLING PUMP LCS INTERLOCK 1=REMOTE, 0=LOCAL
4 CVB-001 REDUCER CIRCULATION PUMP LCS INTERLOCK 1=REMOTE, 0=LOCAL
5 CVB-001 BELT RIP DETECTOR ENABLE 1=ENABLE, 0=DISABLE
Rev B 18-Mar-11
Page 85 of 180
Conveying System
Control Narrative
6 CVB-001 METAL DETECTOR ENABLE 1=ENABLE, 0=DISABLE

7;15 SPARE
4 0 CVB-002 CONVEYOR TAIL LCS INTERLOCK 1=REMOTE, 0=LOCAL
1 CVB-002 CONVEYOR PRIMARY DRIVE LCS INTERLOCK 1=REMOTE, 0=LOCAL
2 CVB-002 CONVEYOR SECONDARY DRIVE LCS INTERLOCK 1=REMOTE, 0=LOCAL
3 CVB-0002 DRIVE MAINTENANCE INTERLOCK 1=NO MAINT,0=MAINT
4 CVB-002 REDUCED SPEED MODE 1=REDUCED,0=NORMAL
5 CVB-001 BELT RIP DETECTOR ENABLE 1=ENABLE, 0=DISABLE
6;15 SPARE
6 0 CVB-002 DRIVE #1 ENABLE 1=ENABLE, 0=DISABLE
1 CVB-002 DRIVE #1 BLOWER #1 INTERLOCK 1=REMOTE, 0=LOCAL
5;15 SPARE
8 0 CVB-002 DRIVE #1 ENABLE 1=ENABLE, 0=DISABLE
5;15 SPARE
10 0 CVB-001 CONVEYOR MODE 1=AUTO, 0=MANUAL
1 CVB-001 CONVEYOR MANUAL PRE-START 0 -> 1, MOMENTARY
2 CVB-001 CONVEYOR MANUAL START 0 -> 1, MOMENTARY
3 CVB-001 CONVEYOR STOP 0=STOP, 1=NO STOP
4;15 SPARE
12 0 CVB-002 CONVEYOR MODE 1=AUTO, 0=MANUAL
1 CVB-002 CONVEYOR MANUAL PRE-START 0 -> 1, MOMENTARY
2 CVB-002 CONVEYOR MANUAL START 0 -> 1, MOMENTARY
3 CVB-002 CONVEYOR STOP 0=STOP, 1=NO STOP
4;15 SPARE
14 0 SYSTEM PRE-START 0 -> 1, MOMENTARY
1 SYSTEM START 0 -> 1, MOMENTARY
2 SYSTEM EMPTY STOP 0=STOP, 1=NO STOP
3 SYSTEM SEQUENCE STOP 0=STOP, 1=NO STOP
4 SYSTEM IMMEDIATE STOP 0=STOP, 1=NO STOP
5;15 SPARE
16 0 WARNING/ALARM RESET 0 -> 1, MOMENTARY
1 BELT SCALE TOTAL RESET 0 -> 1, MOMENTARY
2;15 SPARE
Table 30: DCS to PLC commands
Rev B 18-Mar-11
Page 86 of 180
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Control Narrative
The following table shows the PLC to DCS status.
DB Bit Description Values

Offset No.
0 COMMUNICATIONS HEARTBEAT 0-65535, COUNT UP
2 CVB-001 CONVEYOR LCS STATUS 0=OFF,1=AUTO, 2=HAND
4 CVB-001 MOTOR BLOWER LCS STATUS 1=AUTO, 2=MAINTENANCE
6 CVB-001 THRUSTER BRAKE LCS STATUS 1=AUTO, 2=MAINTENANCE
8 CVB-001 REDUCER COOLING PUMP LCS STATUS 1=AUTO, 2=MAINTENANCE
10 CVB-001 REDUCER CIRCULATION PUMP LCS STATUS 1=AUTO, 2=MAINTENANCE
12 CVB-002 CONVEYOR TAIL LCS STATUS 0=OFF,1=AUTO, 2=HAND
14 CVB-002 CONVEYOR PRIMARY DRIVE LCS STATUS 0=OFF,1=AUTO, 2=HAND
16 CVB-002 CONVEYOR SECONDARY DRIVE LCS STATUS 0=OFF,1=AUTO, 2=HAND
18 CVB-002 WINCH LCS STATUS 1=AUTO, 2=MAINTENANCE
20 CVB-001 CONVEYOR PERMISSIVE 0=READY
1=INTERLOCKED
2=FAULT
22 CVB-001 CONVEYOR STATUS 0=STOPPED
1=STARTING
2 =RUNNING
3-RUNNING WITH WARNING
4=RUNNING WITH FAULT
5=STOPPING
24 CVB-002 CONVEYOR PERMISSIVE 0=READY
1=INTERLOCKED
2=FAULT
26 CVB-002 CONVEYOR STATUS 0=STOPPED
1=STARTING
2 =RUNNING
5=STOPPING
28 CVB-002 WINCH PERMISSIVE 0=READY
1=INTERLOCKED
2=FAULT
30 CVB-002 WINCH STATUS 0=STOPPED
1=STARTING
2 =RUNNING
Rev B 18-Mar-11
Page 87 of 180
Conveying System
Control Narrative

5=STOPPING
32 0 CVB-001 MOTOR BLOWER STATUS 1=RUN, 0=STOP
1 CVB-001 THRUSTER BRAKE STATUS 1=RUN, 0=STOP
2 CVB-001 REDUCER COOLING PUMP STATUS 1=RUN, 0=STOP
3 CVB-001 REDUCER CIRCULATION PUMP STATUS 1=RUN, 0=STOP
4;15 SPARE
34 0 CVB-002 MOTOR #1 BLOWER #1 STATUS 1=RUN, 0=STOP
1 CVB-002 MOTOR #1 BLOWER #2 STATUS 1=RUN, 0=STOP
8 CVB-002 MOTOR #1 COOLING SYSTEM STATUS 1=ON, 0=OFF
9 CVB-002 MOTOR #2 COOLING SYSTEM STATUS 1=ON, 0=OFF
10;15 SPARE
36 0 CVB-002 TAIL END BRAK EOPEN 1=OPEN, 0=CLOSED
1 CVB-002 PRIMARY PULLEY BRAKE OPEN 1=OPEN, 0=CLOSED
2 CVB-002 SECONDARY PULLEY BRAKE OPEN 1=OPEN, 0=CLOSED
3 CVB-002 BRAKE SYSTEM FAULT 1=FAULT,0=NORMAL
4;15 SPARE
38 CVB-001 CONVEYOR SPEED 0-32000, TBD
40 CVB-001 PULLEY TEMPERATURE RTD #2 0-32000, TBD
42 CVB-001 PULLEY TEMPERATURE RTD #1 0-32000, TBD
44 CVB-001 REDUCER TEMPERATURE RTD #2 0-32000, TBD
48 CVB-001 REDUCER TEMPERATURE RTD #1 0-32000, TBD
50 CVB-001 MOTOR BEARING #1 RTD 0-32000, TBD
52 CVB-001 MOTOR BEARING #2 RTD 0-32000, TBD
54 CVB-001 MOTOR WINDING #1 RTD #1 0-32000, TBD
66 CVB-002 HEAD END PULLEY TEMPERATURE RTD #1 0-32000, TBD
68 CVB-002 HEAD END PULLEY TEMPERATURE RTD #2 0-32000, TBD
70 CVB-002 SECONDARY DRIVE PULLEY TEMP, RTD #1 0-32000, TBD
72 CVB-002 SECONDARY DRIVE PULLEY TEMP. RTD #2 0-32000, TBD
74 CVB-002 RETURN PULLEY TEMPERATURE RTD #1 0-32000, TBD
76 CVB-002 RETURN PULLEY TEMPERATURE RTD #2 0-32000, TBD
78 CVB-002 PRIMARY DRIVE PULLEY TEMP. RTD #1 0-32000, TBD
Rev B 18-Mar-11
Page 88 of 180
Conveying System
Control Narrative
82 CVB-002 PRIMARY DRIVE MOTOR WINDING #1 RTD #1 0-32000, TBD

94 CVB-002 PRIMARY DRIVE AIR OUTLET RTD 0-32000, TBD
96 CVB-002 PRIMARY DRIVE AIR INLET RTD #1 0-32000, TBD
98 CVB-002 PRIMARY DRIVE AIR INLET RTD #2 0-32000, TBD
100 CVB-002 TAIL PULLEY TEMPERATURE RTD #1 0-32000, TBD
102 CVB-002 TAIL PULLEY TEMPERATURE RTD #2 0-32000, TBD
108 CVB-002 SECONDARY DRIVE MTR WINDING #1 RTD #1 0-32000, TBD
112 CVB-002 SECONDARY DRIVE MTR WINDING #2 RTD #1 -32000, TBD
120 CVB-002 SECONDARY DRIVE AIR OUTLET RTD 0-32000, TBD
122 CVB-002 SECONDARY DRIVE AIR INLET RTD #1 0-32000, TBD
124 CVB-002 SECONDARY DRIVE AIR INLET RTD #2 0-32000, TBD
130 CVB-001 REDUCER VIBRATION STAGE #3 0-32000, TBD
136 CVB-002 SECONDARY DRIVE PULLEY VIBRATION #1 0-32000, TBD
140 CVB-002 PRIMARY DRIVE PULLEY VIBRATION #1 0-32000, TBD
152 CVB-001 DRIVE SPEED 0-32000, TBD
154 CVB-001 DRIVE TORQUE 0-32000, TBD
156 CVB-001 MOTOR BEARING 1 TEMPERATURE 0-32000, TBD
158 CVB-001 MOTOR BEARING 2 TEMPERATURE 0-32000, TBD
160 CVB-001 MOTOR WINDING 1-1 TEMPERATURE 0-32000, TBD
Rev B 18-Mar-11
Page 89 of 180
Conveying System
Control Narrative

172 CVB-002 DRIVE ACTUAL SPEED 0-32000, TBD
174 CVB-002 DRIVE TORQUE 0-32000, TBD
176 CVB-002 MOTOR 1 AIR INLET 1 TEMPERATURE 0-32000, TBD
180 CVB-002 MOTOR 1 AIR OUTLET 2 TEMPERATURE 0-32000, TBD
182 CVB-002 MOTOR 1 WINDING 1-1 TEMPERATURE 0-32000, TBD
198 CVB-002 MOTOR 2 AIR OUTLET 2 TEMPERATURE 0-32000, TBD
212 480V FEEDER PHASE A – VOLTS 0-32000, TBD
214 480V FEEDER PHASE B – VOLTS 0-32000, TBD
216 480V FEEDER PHASE C – VOLTS 0-32000, TBD
218 480V FEEDER PHASE A – CURRENT 0-32000, TBD
220 480V FEEDER PHASE B – CURRENT 0-32000, TBD
222 480V FEEDER PHASE C – CURRENT 0-32000, TBD
224 480V FEEDER AVERAGE POWER 0-32000, TBD
226 CVB-001 SPEED 0-32000, TBD
228 CVB-001 BELT LOAD 0-32000, TBD
230 CVB-001 BELT TOTAL 0-32000, TBD
232 CVB-002 SPEED 0-32000, TBD
234 STOCK PILE LEVEL 0-32000, TBD
236 CVB-001 CONVEYOR WARNINGS (1-16) SEE WARNINGS AND ALARMS
246 CVB-002 WINCH WARNINGS (1-16) SEE WARNINGS AND ALARMS
248 POWER MONITORING WARNINGS (1-16) SEE WARNINGS AND ALARMS
250 POWER MONITORING WARNINGS (17-32) SEE WARNINGS AND ALARMS
252 CVB-001 CONVEYOR ALARMS (1-16) SEE WARNINGS AND ALARMS
Rev B 18-Mar-11
Page 90 of 180
Conveying System
Control Narrative

292 CVB-002 WINCH ALARM STATUS (1-16) SEE WARNINGS AND ALARMS
294 POWER MONITORING ALARMS (1-16) SEE WARNINGS AND ALARMS
302 FIRE SYSTEM ALARMS (1-16) SEE WARNINGS AND ALARMS
Table 31: PLC to DCS status
8.9.3 Communications monitoring
Word 0 in the data interface is used to check DCS to PLC s communications. The DCS and PLC
will continuously update this value by incrementing the count by one. When the full range
count is reached (65,535) the count will start again at 0.
The PLC will monitor the value from the DCS. If the value does not change within 1 second, the
PLC will declare a communications failure. The PLC will set the entire command data table to 0
which will create an immediate stop of all devices. In addition, all LCS s will become operational
to allow local control of the equipment.
The DCS will similarly monitor the PLC communications heartbeat value.
Rev B 18-Mar-11
Page 91 of 180
Conveying System
Control Narrative
9 Safety Systems
The conveyors are equipped with safety devices for protection of operations personnel. All
safety systems are hard-wired to protect against possible failure of the system due to a software
error.
9.1 Emergency Stop circuits
Emergency stop circuits consist of pull cords and emergency stops. Emergency stop buttons are
mounted on the conveyor LCS’s, one for CVB-001 and three for CVB-002
Pull cords are installed along each side of the conveyors. For CVB-001, standard pull cords with
double contacts are used. One contact is wired to a safety relay and the other to the PLC input.
For CVB-002, the pull cords are monitored using an intelligent control system. One hard wired
contact is maintained for safety and is connected to the safety relay. The system monitors all
the pull cords via a bus system. The PLC communicates via Profibus with the monitoring system
to determine to status of the pull cords.
9.1.1 Safety relay
Each conveyor emergency circuit is hard-wired to its own safety relay. The safety relays
interface directly with the conveyor drives.
9.2 Warning strobes and horns
Each conveyor has multiple warning horns an strobes along its entire length. For CVB-001 the
horns and strobes are controlled directly by the PLC. For CVB-002, the horns and strobes are
controlled indirectly from the PLC via the pull cord intelligent control system.
The warning horns sound for 30 seconds prior to the conveyor starting, and are silenced when
motion is detected.
The strobes are activated whenever the conveyor is starting or running. The strobes are only
de-activated when there is no start command and the conveyor is physically stopped.
Rev B 18-Mar-11
Page 92 of 180
Table of Contents
2 PROJECT DATA
2 PROJECT DATA
2.1 CONVEYOR DATA SHEET 96

2.2 DRAWINGS LIST 97
2.3 GENERAL ARRANGEMENT'S 116
2.4 P&ID'S 135
2.5 MECHANICAL EQUIPMENT LIST 145
Table of Contents 2 Project Data
Page 93 of 180
100AR002-K
Mechanical / Structural drawing list

SELLER Name: ThyssenKrupp Robins Inc.
PO Number: 25580-220-POA-MHCB-00001 Rev. 1
Date: 2/21/2011
SELLER SELLER Doc. DDR N° - Initial Submittal SELLER Project

So Sheet N° Comments
Document N° Rev Status Doc Type Schedule Date Code (1) Document N°
SKETCHES
CONVEYOR 0220-CVB-0001 PROPOSED HEAD END A 7 23-Apr-10
050SK002 MODIFICATION SKETCH
GENERAL
100AR002 DRAWING LIST J 1 30-Aug-11
0 6 20-Aug-10
102SR002 GENERAL NOTES AND ABBREVIATIONS STRUCTURAL STEEL
104AR002 SITE PLAN 0 7 26-May-11
106AR002 CONVEYOR DATA SHEET 0 13 21-Sep-11
108AR002 MECHANICAL EQUIPMENT LIST D 66 23-Aug-11
72" SACRIFICIAL CONVEYOR 0220-CVB-0001

200AR002 GENERAL ARRANGEMENT SH.1 1 7 6-Sep-11
202AR002 GENERAL ARRANGEMENT SH.2 1 7, 68 6-Sep-11
204AR002 Available
206AR002 ELECTR. DEVICES LAYOUT A 38 26-Jan-11
208MR002 TAIL END PULLEY FRAME 3 7 15-Jul-11
209MR002 TAIL END STRUCTURE SH. 1 4 7 20-May-11
210MR002 TAIL END STRUCTURE SH. 2 4 7 20-May-11
211MR002 TAIL END SECTIONS SH.1 4 7 9-Jun-11
212MR002 TAIL END STRUCTURE DETAILS SH.1 2 10 20-May-11
213MR002 TAIL END SECTIONS SH.2 1 7 20-May-11
214MR002 IMPACT IDLERS SUPPORT FRAME 1 10 20-May-11
216MR002 SKIRTBOARD SH.1 1 7 9-Jun-11
© Bechtel Corporation 2009. All rights reserved.Bechtel Confidential. Contains information that is confidential and proprietary to Bechtel or its affiliates and may not be
Page 94 of 180
used without Bechtel's prior written permission.
100AR002-K

Date: 2/21/2011

218MR002 SKIRTBOARD SH.2 3 7 15-Jul-11
220MR002 SKIRTBOARD NO. 1 AND DETAILS 0 7 13-May-11 Dwg. added 3/18/11
222MR002 MECHANICAL BELT RIP DETECTOR 0 7 30-Mar-11
224MR002 DECK SECTION BELT SCALE 2 8 2-Aug-11
226MR002 DECK SECTION VULCANIZING PRESS 2 8 20-May-11
227MR002 DECK SECTION VULCANIZING PRESS DETAILS 1 10 13-May-11
228MR002 DECK SECTION METAL DETECTOR 2 8 15-Jul-11
229MR002 DECK SECTION CALIBRATION SUPPORT SH.1 0 8 1-Apr-11
230MR002 DECK SECTION CALIBRATION SUPPORT SH.2 1 8 8-Aug-11
231MR002 DECK SECTION VERTICAL CURVE 2 8 13-May-11
232MR002 SPECIAL DECK SECTION SH. 1 3 8 20-May-11
233MR002 SPECIAL DECK SECTION SH. 2 3 8 20-May-11
234MR002 DECK SECTION DETAILS SH. 1 2 10 20-May-11
236MR002 Available
238MR002 TAKE-UP CARRIAGE W/ COUNTERWEIGHT 2 7 9-Jun-11
240MR002 Available
242SR002 TRUSS TR1 PLANS, ELEVATION AND SECTIONS 2 10 13-May-11 Name change 5/13/11
243SR002 GUARD SECTIONS AND DETAILS FOR TRUSS T-1/T-2/T-3 1 10 13-May-11 Name change 5/13/11
244SR002 TRUSS T-2 PLANS, ELEVATIONS & SECTIONS 1 10 13-May-11 Name change 5/13/11
245SR002 GUARD ELEVATION FOR TRUSS T-1/T-2/T-3 2 10 13-May-11 Name change 5/13/11
246SR002 TRUSS T-3 PLANS, ELEVATIONS & SECTIONS 3 10 13-May-11 Name change 5/13/11
3 10 13-May-11
247SR002 TRUSSES TR1, TR2, AND TR3 SECTIONS AND DETAILS SH. 1
2 10 13-May-11
248SR002 TRUSSES TR1, TR2, AND TR3 SECTIONS AND DETAILS SH. 2
250SR002 BENTS B1, B2, SECTIONS AND DETAILS SH. 1 4 7 18-Jul-11
251SR002 BENTS B1, B2, SECTIONS AND DETAILS SH. 2 2 8 18-Jul-11
Page 95 of 180
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Date: 2/21/2011

252SR002 Available
254SR002 Available
256SR002 Available
258SR002 Available
260MR002 HEAD END DECK SECTION 2 8 13-May-11
261MR002 HEAD END DECK SECTION DETAILS 1 8 13-May-11
262MR002 HEAD PULLEY FRAME 1 7 13-May-11
263MR002 ALIGNMENT SWITCH SUPPORT DETAILS 0 10 13-May-11 Dwg. added 3/30/11
264MR002 HEAD CHUTE SH.1 3 7 2-Aug-11
266MR002 HEAD CHUTE SH.2 3 7 2-Aug-11
268MR002 HEAD CHUTE DETAILS 3 10 2-Aug-11
269MR002 BELT REEL STAND ARRANGEMENT 0 7 5-Aug-11
270MR002 BELT REEL STAND AND PLATFORM DETAILS 1 10 1-Sep-11
271MR002 BELT REEL STAND TYPICAL DETAILS SH. 1 0 10 5-Aug-11
274CR002 FOUNDATION PLAN 1 7 12-Jul-11
276CR002 FOUNDATION DETAILS SH.1 0 7 15-Jul-11
277CR002 FOUNDATION DETAILS SH.2 1 7 12-Jul-11
278CR002 FOUNDATION LOAD TABLE 2 7 2-Aug-11
TRANSFER TOWER
300AR002 GENERAL ARRANGEMENT SH.1 0 7 26-May-11
302AR002 GENERAL ARRANGEMENT SH.2 0 7 26-May-11
304SR002 PLANS (SH .1) 4 7 15-Jul-11
305SR002 PLANS (SH .2) 4 7 10-Aug-11
306SR002 ELEVATIONS (SH. 1) 3 7 15-Jul-11
307SR002 ELEVATIONS (SH. 2) 2 7 26-May-11
Page 96 of 180
100AR002-K

Date: 2/21/2011

308SR002 DETAILS (SH. 1) 3 7 10-Aug-11
309SR002 DETAILS (SH. 2) 1 7 23-Mar-11
310SR002 COUNTERWEIGHT GUARDS (SH. 1) 1 7 13-May-11
311SR002 COUNTERWEIGHT GUARDS (SH. 2) 0 7 24-Jan-11
312SR002 BASE PLATE DETAILS 2 7 15-Jul-11
313SR002 DETAILS SH.3 2 7 16-Jun-11 Dwg. added 3/18/11
54" OVERLAND CONVEYOR 0220-CVB-0002

401AR002 BILL OF MATERIAL 0 68 5-Aug-11
409AR002 E-HOUSE GENERAL ARRANGEMENT 0 7 5-Aug-11
416AR002 ELECTR. DEVICES LAYOUT SH.1 A 23 26-Jan-11
418AR002 ELECTR. DEVICES LAYOUT SH.2 A 23 26-Jan-11
419MR002 TAIL END STRUCTURE SH. 1 6 7 1-Sep-11
420MR002 TAIL END STRUCTURE SH. 2 (DECK) 2 7 16-Jun-11
Page 97 of 180
100AR002-K

Date: 2/21/2011

421MR002 IMPACT IDLERS SUPPORT FRAME 0 7 13-May-11
422MR002 TAIL PULLEY & DISC BRAKE GUARDS 0 10 21-Jun-11
424MR002 TAIL PULLEY SUPPORT FRAME 4 7 15-Jul-11 Dwg. added 3/4/11
425MR002 LOADING CHUTE SH.1 0 7 13-Jun-11
428MR002 SKIRTBOARD 1 7 15-Sep-11
429MR002 SKIRTBOARD SECTIONS & DETAILS 2 10 15-Jul-11
430MR002 SKIRTBOARD DETAILS SH. 1 2 10 9-Jun-11
431MR002 SKIRTBOARD DETAILS SH. 2 1 10 15-Sep-11
432MR002 MECHANICAL BELT RIP DETECTOR 1 7 26-Aug-11
433MR002 HEAD CHUTE DETAILS (LINERS) 0 7 16-Jun-11
436SR002 TAKE-UP FRAME DETAILS SH. 1 1 10 9-Sep-11
437SR002 TAKE-UP FRAME DETAILS SH. 2 0 10 21-Jul-11
438SR002 TAKE-UP FRAME DETAILS SH. 3 1 10 17-Aug-11
440SR002 TAKE-UP FRAME DETAILS SH. 5 0 10 21-Jul-11 Dwg. added 3/23/11
441SR002 TAKE-UP FRAME DETAILS SH. 6 0 10 21-Jul-11 Dwg. added 3/23/11
442SR002 TAKE-UP FRAME SECTIONS SH. 1 0 10 21-Jul-11 Dwg. added 3/23/11
444MR002 TAKE-UP CARRIAGE 0 7 5-Aug-11
445SR002 TAKE-UP FRAME GARDS SH. 1 1 10 21-Sep-11
446MR002 TAKE-UP CARRIAGE DETAILS 0 10 5-Aug-11
447SR002 TAKE-UP FRAME GARDS SH. 2 0 10 17-Aug-11
448MR002 SPECIAL DECK DEFLECTION PULLEYS SH. 1 2 10 29-Jun-11 Dwg. added 3/4/11
449SR002 SPECIAL DECK DEFLECTION PULLEYS SH. 2 0 10 13-May-11 Dwg. added 3/4/11
450MR002 DECK SECTION VULCANIZING PRESS 2 10 29-Jun-11 Dwg. added 3/18/11
451MR002 GUARDS AT VULCANIZING PRESS AND DEFLECTION PULLEYS 0 10 21-Jun-11 Dwg. added 3/18/11
Page 98 of 180
100AR002-K

Date: 2/21/2011

454SR002 Available
456MR002 TAIL TURNOVER 1 7 1-Sep-11
458MR002 Available Included in 456MR002
460MR002 TYPICAL STRAIGHT DECK SECTION 2 8 7-Jun-11
461MR002 HOOD COVER INSTALLATION NOTES 0 8 21-Dec-10
462MR002 SPECIAL DECK SECTION AT RIVER CROSSING 2 8 29-Jun-11
464MR002 Available
466MR002 SPECIAL DECK SECTION AT HEAD END SH. 1 2 8 20-Sep-11
467MR002 SPECIAL HEAD DECK DEFLECTION PULLEYS SH. 2 3 8 20-Sep-11
468MR002 SPECIAL DECK SECTION AT HEAD END SH. 2 2 8 20-Sep-11
470MR002 DECK SECTION DETAILS SH. 1 1 8 9-Jun-11
471MR002 MIDPOINT NETWORK BRIDGE CABINET MOUNTING A 8 20-Sep-11
473MR002 HEAD END BRAKE BRACKETS 3 10 1-Sep-11
474MR002 HEAD TURNOVER 1 7 1-Sep-11
476MR002 HEAD TURNOVER DETAILS 2 10 1-Sep-11
477MR002 HEAD PULLEY REMOVAL CARRIAGE A 7 11-May-11
482SR002 DRIVE STATION PULLEY FRAMES SH. 1 1 7 20-Sep-11
485SR002 DRIVE STATION ACCESS PLATFORM SH.1 0 7 1-Sep-11
486SR002 DRIVE STATION ACCESS PLATFORM SH.2 0 7 1-Sep-11
487SR002 DRIVE STATION ACCESS PLATFORM DETAILS 0 10 1-Sep-11
488MR002 DRIVE STATION GUARDS SH.1 2 10 1-Sep-11
489MR002 DRIVE STATION GUARDS SH.2 0 10 21-Jun-11
490SR002 HEAD END TRUSS T-9 - T-11 PLANS & ELEV. 1 10 5-Aug-11
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491SR002 HEAD END TRUSS T-12 & T-13 PLANS & ELEV. 1 10 5-Aug-11
492SR002 HEAD END TRUSS T-14 PLANS AND ELEVATIONS 1 10 5-Aug-11
493SR002 HEAD END TRUSS T-15 PLANS AND ELEVATIONS 1 10 5-Aug-11
494SR002 HEAD END TRUSS T-9 THROUGH T-15 SECTIONS 1 10 5-Aug-11
495SR002 HEAD END TRUSS T-9 THROUGH T-15 DETAILS 1 10 5-Aug-11
496SR002 HEAD END TRUSS T-16 1 10 12-Sep-11
498SR002 HEAD END TRUSS T-18 0 10 26-May-11
500SR002 HEAD END TRUSS T-20 1 10 18-Aug-11
501SR002 HEAD END TRUSS T-21 1 10 18-Aug-11
502SR002 HEAD END TRUSS T-16 THROUGH T-21 SECTIONS 0 10 26-May-11
503SR002 HEAD END TRUSS T-16 THROUGH T-21 DETAILS SH. 1 1 10 18-Aug-11
504SR002 HEAD END TRUSS T-16 THROUGH T-21 DETAILS SH. 2 0 10 26-May-11 Dwg. added 4/21/11
505SR002 HEAD END TRUSS T-16 THROUGH T-21 DETAILS SH. 3 1 10 12-Sep-11 Dwg. added 4/21/11
506SR002 HEAD END TRUSS T-22 PLANS AND ELEVATIONS B 10 9-Jun-11
507SR002 MAINTENANCE PLATFORM 0 10 12-Sep-11
508SR002 HEAD END TRUSS T-23 PLANS AND ELEVATIONS B 10 9-Jun-11
509SR002 HEAD END TRUSS T-22 SECTIONS 0 10 12-Sep-11
510SR002 HEAD END TRUSS T-22 - T-23 DETAILS SH. 1 B 10 9-Jun-11
511SR002 HEAD END BELT TENSIONING BENT/PLATFORM PLANS & 0 7 9-Sep-11
DETAILS
512SR002 HEAD END BENTS GRIDLINES 254-290 0 7 9-Sep-11
513SR002 HEAD END BENTS B-12 & B-13 1 7 9-Sep-11
516SR002 HEAD END BENT B-18 1 10 9-Sep-11
517SR002 HEAD END BENT B-19 1 10 9-Sep-11
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518SR002 HEAD END BENT DETAILS SH. 1 1 10 9-Sep-11
520SR002 HEAD END BENT DETAILS SH. 3 0 10 12-Aug-11
521SR002 HEAD END BELT PULLING PLATFORM PLAN & DETAILS 1 7 9-Sep-11
524SR002 STACKER SUPPORT TOWER PLAN (SH. 1) C 7 2-Sep-11
525SR002 STACKER SUPPORT TOWER PLAN (SH. 2) C 7 2-Sep-11
526SR002 STACKER SUPPORT TOWER ELEVATIONS (SH. 1) C 7 2-Sep-11
527SR002 STACKER SUPPORT TOWER ELEVATIONS (SH. 2) C 7 2-Sep-11
528SR002 STACKER SUPPORT TOWER SECTIONS C 10 2-Sep-11
529SR002 STACKER SUPPORT STRUCTURE CONNECTION DETAILS AND A 10 2-Sep-11
SECTIONS
530SR002 STACKER SUPPORT TOWER DETAILS (SH. 1) C 10 2-Sep-11
531SR002 STACKER SUPPORT TOWER DETAILS (SH. 2) B 10 2-Sep-11
532SR002 HEAD END TURNOVER PULLEY GUARDS 0 10 9-Sep-11
533SR002 HEAD END TURNOVER PULLEY GUARD DETAILS 0 10 9-Sep-11
534SR002 Available Included in 536MR002
535SR002 Available for STACKER SUPPORT TOWER GUARDS Included in 536MR002
536MR002 BELT CLEANER MOUNTING ARRANGEMENT & DETAILS 0 7, 10 5-Aug-11
538MR002 BELT REEL STATION SH. 1 0 8 8-Aug-11
Name change VUL-
539MR002 BELT REEL STATION SH. 2 1 8 1-Sep-11 CANIZING PRESS
540MR002 BELT REEL STATION SH. 3 0 8 8-Aug-11 moved to 450MR817
541MR002 BELT REEL STATION SH. 4 0 8 8-Aug-11
542CR002 TAIL-END FOUNDATION PLAN 1 7 22-Sep-11
544CR002 TAIL-END FOUNDATION DETAILS SH. 1 2 7 8-Sep-11
545CR002 TAIL-END FOUNDATION DETAILS SH. 2 1 7 18-Aug-11
546CR002 TAIL-END FOUNDATION LOAD TABLE SH. 1 1 7 10-Aug-11
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547CR002 TAIL-END FOUNDATION LOAD TABLE SH. 2 1 7 10-Aug-11
548CR002 HEAD-END FOUNDATION PLAN 2 7 22-Sep-11
549CR002 HEAD-END FOUNDATION DETAILS SH. 1 0 7 22-Jun-11
550CR002 HEAD-END FOUNDATION DETAILS SH. 2 2 7 8-Sep-11
551CR002 HEAD-END FOUNDATION DETAILS SH. 3 1 7 20-Sep-11 Dwg. added 3/30/11
552CR002 HEAD-END FOUNDATION LOAD TABLE SH. 1 2 7 20-Sep-11
553CR002 HEAD-END FOUNDATION LOAD TABLE SH. 2 D 7 12-May-11
554CR002 HEAD-END FOUNDATION DETAILS SH. 4 1 10 20-Sep-11 Dwg. added 3/30/11
555CR002 TYP. OVERLAND CROSS-OVER FOUND. LOAD TABLE & 2 10 9-Sep-11
DETAILS
556CR002 ELECTRICAL AREA FOUNDATION PLAN & DETAILS 0 10 10-Aug-11
557CR002 ELECTRICAL AREA FOUNDATION LOAD TABLE 0 7 10-Aug-11
558SR002 ELECTRICAL AREA - ACCESS PLATFORMS 1 7 21-Sep-11
560SR002 TAIL-END TRUSS T-1 3 7 11-Aug-11
561SR002 TAIL-END TRUSS T-2 0 7 23-Mar-11
563SR002 TAIL-END TRUSS T-4 & WALKWAYS TO TRUSS T-5 0 7 23-Mar-11
566SR002 TAIL-END TRUSS T-7 & T-8 0 7 23-Mar-11
567SR002 TAIL-END TRUSS T-7 & T-8 SECTIONS 0 7 23-Mar-11
568SR002 TAIL-END TRUSSES TYPICAL DETAILS SH. 1 0 7 23-Mar-11
569SR002 TAIL-END TRUSS T-1 SECTIONS 2 7 11-Aug-11
570SR002 TAIL-END TRUSSES T-2 THRU T-6 SECTIONS 0 7 23-Mar-11
571SR002 TAIL-END TRUSSES TYPICAL DETAILS SH. 2 0 7 23-Mar-11
573SR002 TAIL-END BENTS B-1 & B-2 1 7 28-Jul-11
574SR002 TAIL-END BENT B-3 1 7 28-Jul-11
575SR002 TAIL-END BENTS B-4 & B-5 1 7 28-Jul-11
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576SR002 TAIL-END BENT B-6 1 7 28-Jul-11
577SR002 TAIL END BENT B-7 & PIER AT COLUMN LINE 205 3 7 28-Jul-11
579SR002 STACKER OVERALL PLAN B 9-Sep-11 Dwg. added 9/9/11
580SR002 STACKER OVERALL ELEVATION C 7 8-Sep-11
581SR002 STACKER PLANS AND ELEV.-SECT. 1 C 7 8-Sep-11
585SR002 STACKER PLANS AND ELEV.-SECT. 5 SH. 1 C 7 13-Sep-11
586SR002 STACKER PLANS AND ELEV.-SECT. 5 SH. 2 C 7 13-Sep-11
587SR002 PULLEY MAINTENANCE TOWER PLANS SH. 1 C 7 9-Sep-11
588SR002 PULLEY MAINTENANCE TOWER PLANS SH. 2 C 7 9-Sep-11
589SR002 PULLEY MAINTENANCE TOWER ELEVATIONS SH. 1 C 7 9-Sep-11
590SR002 PULLEY MAINTENANCE TOWER ELEVATIONS SH. 2 C 7 9-Sep-11
591SR002 STACKER DETAILS (SH. 1) C 10 8-Sep-11
594SR002 PULLEY MAINTENANCE TOWER DETAILS SH. 2 C 10 8-Sep-11
595SR002 HEAD END TRUSS T-22 - T-23 DETAILS SH. 2 0 10 12-Sep-11
596SR002 HEAD END TRUSS T-23 SECTIONS B 8 10-Jun-11
597SR002 HEAD END TRUSS T-23 SECTIONS & DETAILS B 8, 10 10-Jun-11
598SR002 HEAD END TRUSS T-23 DETAILS SH. 1 B 10 10-Jun-11
599SR002 HEAD END TRUSS T-23 DETAILS SH. 2 B 10 10-Jun-11
600SR002 STACKER DETAILS SHEET 4 B 10 8-Sep-11
601SR002 Available for STACKER DETAILS SHEET 5 B 10
604SR002 Available for PULLEY LIFTING FRAME B 10
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MANUALS AND MISC.

610MR002 LUBRICATION SCHEDULE A 16 5-Aug-11
612MR002 SPARE PARTS LIST 16-May-11 63, 64 16-May-11
614MR002 SPECIAL TOOLS LIST 66 31-Aug-11
616MR002 Available moved to 108AR002
620MR002 O & M MANUALS 60, 61 28-Oct-11
700MR002 CONVEYOR INSTALLATION STANDARDS SHEET 1 OF 3 0 56 30-Mar-11 Dwg.added 3/8/11

706SR002 STACKER ERECTION PROCEDURE SH. 1 B 56 12-Aug-11 Dwg.added 8/12/11
711SR002 INSTALL SEQUENCE & PRETENSIONING OF HORIZONTAL B 56 15-Aug-11 Dwg.added 8/15/11
CABLES
CALCULATIONS
800CM002 SACRIFICIAL CONVEYOR STATIC CALCULATION 0 14 10-Aug-11
812CM002 OVERLAND CONVEYOR STATIC CALCULATION I 14 27-Oct-10
816CM002 OVERLAND CONVEYOR DYNAMIC CALCULATION (STOPPING) A 14 24-Jan-11
820CM002 OVERLAND CONVEYOR STATIC AND DYNAMIC REPORT 0 14 5-Aug-11
840CM002 CVB-0001 TO CVB-0002 FLOW SIMULATION F 14 8-Apr-11
850CS002 STRUCTURAL DESIGN CRITERIA 0 14 16-Sep-10
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851CS002 STEEL FABRICATION SPECIFICATION 0 14 20-Jan-11
859CS002 STRUCTURAL DEPT. DESIGN MANUAL #8 (STACKER 0 14 15-Sep-11
CALCULATION)
860CS002 OVERLAND CONVEYOR STRUCTURAL CALCULATION Included in 859CS002
TYPICAL
900MR002 TYP. PILLOW BLOCK SEAT 0 10 13-May-11
902MR002 Available moved
906MR002 Available
908MR002 TYPICAL SKIRTBOARD DETAILS SH. 1 1 10 1-Apr-11
909MR002 TYPICAL SKIRTBOARD DETAILS SH. 2 1 10 1-Apr-11 Dwg.added 3/8/11
914MR002 Available
916MR002 Available
918MR002 Available
Available, Dwg. BELT
920MR002 Available REEL STAND is
922MR002 Available moved to 538MR817 -
924MR002 Available 540MR817
925SR002 72" SACRIFICIAL CONVEYOR 0220-CVB-0001 CONVEYOR 1 10 18-Mar-11
CROSSOVER
926SR002 54" OVERLAND CONVEYOR 0220-CVB-0002 CONVEYOR 3 10 1-Sep-11
CROSSOVER SH. 1
927SR002 54" OVERLAND CONVEYOR 0220-CVB-0002 CONVEYOR 3 10 9-Sep-11
CROSSOVER SH. 2
928SR002 TYPICAL STAIR DETAILS 1 10 16-Sep-10
930SR002 TYPICAL HANDRAIL DETAILS 0 10 22-Sep-10
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932SR002 TYPICAL LADDER DETAILS 1 10 26-Aug-10
933SR002 TYPICAL BENT BRACING 0 10 18-Aug-11
934SR002 TYPICAL CONNECTION DETAILS SH. 1 (VERTICAL BRACING) 0 10 18-Aug-10
935SR002 TYPICAL CONNECTION DETAILS SH. 2 (VERTICAL BRACING) 0 10 22-Sep-10
936SR002 TYPICAL HORIZONTAL BRACING CONNECTIONS 0 10 3-Sep-10
937SR002 TYPICAL BEAM CONNECTIONS 0 11 3-Sep-10
938CR002 SACRIFICIAL CONV. TYPICAL SLEEPER DETAILS 0 10 10-Aug-11
939CR002 OVERLAND CONV. TYPICAL SLEEPER DETAILS 0 11 15-Mar-11
ERECTION
450MR002_01 DECK SECTION VULCANIZING PRESS-ELEVATION, SECTION & A 10
DETAILS CONVEYOR 0220-CVB-0002
450MR002_02 DECK SECTION VULCANIZING PRESS-GUARDS, SECTIONS A 10
AND DETAILS CONVEYOR 0220-CVB-0002
460MR002-M01 54" OVERLAND CONVEYOR 0220-CVB-0002, TYPICAL DECK 2 10
SECTION - ELEVATION, 460MR002-M01
460MR002-M02 54" OVERLAND CONVEYOR 0220-CVB-0002, TYPICAL DECK 2 10
SECTION - GUARD, 460MR002-M02
462MR002-M01 54" OVERLAND CONVEYOR 0220-CVB-0002, SPECIAL DECK 2 10
SECTION - ELEVATION, 462MR002-M01
462MR002-M02 54" OVERLAND CONVEYOR 0220-CVB-0002, SPECIAL DECK 1 10
SECTION - GUARD, 462MR002-M02
470MR002-M01 54" OVERLAND CONVEYOR 0220-CVB-0002 PULL CORD A 10
SWITCH BRACKET
925SR002-M01 72" CONVEYOR- STRUCTURE- PLAN AND ELECATION 0 10
925SR002-M02 72" CONVEYOR-GRATING & HANDRAIL PLAN, ELEVATION AND 0 10
DETAIL
926SR002-M01 54" OVERLAND STRUCTURE PLAN AND ELEVATION 0 10
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926SR002-M02 54" OVERLAND GRATING AND HANDRAIL PLAN, ELEVATION 0 10
AND DETAIL
927SR002-M01 54" OVERLAND STRUCTURE TYPE B PLAN AND ELEVATION 0 10
927SR002-M02 54" OVERLAND STRUCTURE TYPE C PLAN AND ELEVATION 0 10
927SR002-M03 54" OVERLAND STRUCTURE TYPE D PLAN AND ELEVATION 0 10
927SR002-M04 54" OVERLAND STRUCTURE TYPE E PLAN AND ELEVATION 0 10
927SR002-M05 54" OVERLAND STRUCTURE TYPE B PLAN, ELEVATION, 0 10

SECTION AND DETAIL
927SR002-M06 54" OVERLAND GRATING AND HANDRAIL TYPE C PLAN, 0 10
ELEVATION AND DETAIL
927SR002-M07 54" OVERLAND GRATING AND HANDRAIL TYPE D PLAN, 0 10
ELEVATION AND DETAIL
927SR002-M08 54" OVERLAND STRUCTURE GRATING AND HANDRAIL TYPE E 0 10
PLAN, ELEVATION AND DETAIL
E208MR002 TAIL PULLEY FRAME - ELEVATIONS, SECTION & GUARDS A 10
E209MR002_01 TAIL END STRUCTURE - DRIBBLE CHUTE ELEVATIONS & A 10
SECTIONS
E209MR002_02 TAIL END STRUCTURE DRIBBLE CHUTE GUARDS - A 10
ELEVATIONS & SECTIONS
E210MR002_01 TAIL END STRUCTURE - LOADING CHUTE ELEVATIONS & A 10
SECTIONS
E210MR002_02 TAIL END STRUCTURE LOADING CHUTE GUARDS - A 10
ELEVATIONS & SECTIONS
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E214MR002 IMPACT IDLERS SUPPORT FRAME - ELEVATIONS & A 10
SECTIONS
E216MR002 Erection Conveyor 0020CVB-0001 SKIRTBOARD DRIBBLE A 10
CHUTE - ELEVATIONS & DETAILS
E218MR002 Erection Conveyor 0020CVB-0001 SKIRTBOARD LOADING A 10
CHUTE - ELEVATIONS & DETAILS
E220MR002 Erection Conveyor 0020CVB-0001 SKIRTBOARD N1 A 10
ELEVATIONS&SECTIONS
E224MR002 Erection Conveyor 0020CVB-0001 METAL DETECTOR DECK A 10
SECTION
E226MR002 DECK SECTION-VULCANIZING PRESS-ELEVATIONS AND A 10
SECTIONS
E226MR002G DECK SECTION-VULCANIZING PRESS-GRATINGS A 10
E226MR002HR DECK SECTION-VULCANIZING PRESS - HANDRAILS A 10
E228MR002 Erection Conveyor 0020CVB-0001 METAL DETECTOR BELT A 10
SCALE
E231MR002 Erection Conveyor 0020CVB-0001 DECK SECTION VERTICAL A 10
CURVE
E232MR002 SPECIAL DECK SECTION - ELEVATIONS & SECTIONS A 10
E232MR002G SPECIAL DECK SECTION - GRATINGS A 10
E232MR002HR SPECIAL DECK SECTION - HANDRAILS A 10
E233MR002 SPECIAL DECK SECTION - ELEVATIONS AND SECTIONS A 10
E233MR002G SPECIAL DECK SECTION - GRATINGS A 10
E233MR002HR SPECIAL DECK SECTION - HANDRAILS A 10
E238MR002 PLANOS DE MONTAJE COUNTERWEIGHT-PLANS & A 10
ELEVATIONS
E242SR002 HEAD TRUSSES - TRUSS T1 - ELEVATIONS & SECTIONS A 10
E242SR002G HEAD TRUSSES - TRUSS T1 - GRATINGS A 10
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E242SR002HR HEAD TRUSSES - TRUSS T1 - HANDRAILS A 10
E244SR002 HEAD TRUSSES - TRUSS T2 - ELEVATIONS & SECTIONS A 10
E244SR002G HEAD TRUSSES - TRUSS T2 - GRATINGS A 10
E245SR002 HEAD TRUSSES - GUARDS - ELEVATIONS, SECTIONS & A 10
DETAILS
E246SR002 HEAD TRUSSES - TRUSS T3 - ELEVATIONS & SECTIONS B 10
E246SR002G HEAD TRUSSES - TRUSS T13- GRATINGS A 10
E250MR002 BENTS - ELEVATIONS & DETAILS A 10
E260MR002_01 PLANOS DE MONTAJE HEAD END DECK SECTION-PLANS & A 10
ELEVATIONS
E260MR002_02 PLANOS DE MONTAJE HEAD END DECK SECTION- A 10
MISCELLANEOUS
E262MR002 PLANOS DE MONTAJE HEAD PULLEY FRAME A 10
E264MR002 HEAD CHUTE ELEVATIONS A 10
E266MR002 HEAD CHUTE HEAD CHUTE DETAILS A 10
E304SR002_01 PLANOS DE MONTAJE TRANSFER TOWER-BASE PLATE PLAN A 10
E304SR002_02 PLANOS DE MONTAJE TRANSFER TOWER-PLAN +3999.415 A 10

E304SR002_03 PLANOS DE MONTAJE TRANSFER TOWER-PLAN +4002.247 A 10
E304SR002_04 PLANOS DE MONTAJE TRANSFER TOWER-PLAN +4004.940 - A 10
DETAILS AND SECTIONS
E304SR002_05 PLANOS DE MONTAJE TRANSFER TOWER-ELEVATIONS A&D A 10
E304SR002_06 PLANOS DE MONTAJE TRANSFER TOWER-ELEVATIONS - A 10
B/C/E
E304SR002_07 PLANOS DE MONTAJE TRANSFER TOWER-ELEVATIONS 122 A 10
@ 125
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E304SR002G PLANOS DE MONTAJE TRANSFER TOWER-GRATINGS A 10
E304SR002HR PLANOS DE MONTAJE TRANSFER TOWER-HANDRAILS A 10
E310SR002 PLANOS DE MONTAJE COUNTERWEIGHT-MISCELLANEOUS A 10
E419MR002 TAIL END STRUCTURE GENERAL & DISTRIBUTION OF BASE A 10

PLATE
E419MR002G TAIL END STRUCTURE GRATINGS A 10
E419MR002HR TAIL END STRUCTURE HANDRAILS A 10
E420MR002_01 TAIL DECK FRAME ELEVATIONS, SECTIONS & DETAILS A 10
E420MR002_02 TAIL DECK FRAME ELEVATIONS, SECTIONS & DETAILS A 10
E421MR002 IMPACT IDLERS SUPPORT FRAME ELEVATIONS, SECTIONS & A 10
DETAILS
E424MR002 TAIL PULLEY SUPPORT FRAME ELEVATIONS, SECTIONS AND A 10
DETAILS
E425MR002 HEAD CHUTE LOADING CHUTE A 10
E428MR002_01 SKRIBOARD 1 @ 4-PLAN & ELEVATION CONVEYOR 0220-CVB- A 10
002
E428MR002_02 SKRIBOARD 1 @ 4-SECTIONS & DETAILS CONVEYOR 0220- A 10
CVB-002
E433MR002 HEAD CHUTE UBICATION OF LINERS A 10
E560SR002 CONVEYOR 0220-CVB-0002 TRUSS T-1 ELEVATIONS, A 10
SECTIONS & DETAILS
E560SR002G CONVEYOR 0220-CVB-0002 TRUSS T-1 GRATINGS A 10
E560SR002HR CONVEYOR 0220-CVB-0002 TRUSS T-1 HANDRAILS A 10
SECTIONS AND DETAILS
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SECTIONS AND DETAILS
SECTIONS & DETAILS
SECTIONS & DETAILS
SECTIONS & DETAILS
E566SR002 CONVEYOR 0220-CVB-0002 TRUSS T-7 & T-8 ELEVATIONS, A 10
SECTIONS & DETAILS
E566SR002G CONVEYOR 0220-CVB-0002 TRUSS T-7 & T-8 GRATINGS A 10
E566SR002HR CONVEYOR 0220-CVB-0002 TRUSS T-7 & T-8 ELEVATIONS, A 10
SECTIONS & DETAILS
E573SR002 CONVEYOR 0220-CVB-0002 BENTS B-1 & B-2 ELEVATIONS, A 10
SECTIONS & DETAILS
E574SR002 CONVEYOR 0220-CVB-0002 BENTS B-3 ELEVATIONS, A 10
SECTIONS & DETAILS
E575SR002 CONVEYOR 0220-CVB-0002 BENTS B-4 & B-5 ELEVATIONS, A 10
SECTIONS & DETAILS
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SECTIONS & DETAILS
SECTIONS & DETAILS
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BECHTEL / XSTRATA
ANTAPACCAY MINE
OVERLAND CONVEYING SYSTEM
MECHANICAL EQUIPMENT LIST
TKRI DRAWING # 108AR002 DATE: 08.16.11
BECHTEL DRAWING # REV: D
PO ITEM ITEM QTY DESCRIPTION LOCATION SUPPLIER TKRI Part # TAG # SUPPLIER DWG #
NUMBER
1.000 1 SACRIFICIAL CONVEYOR 0220-CVB-0001
1.000d 1.01 1 250 KW Reducer Sacrificial Conv. Sumitomo 1002-1001 202AR002/1 PZOD2119
1.000d 1.02 1 Low Speed Coupling for 250KW Reducer Sacrificial Conv. Sumitomo 1002-1002 202AR002/1 TBD
1.000d 1.03 1 High Speed Coupling for 250KW Reducer Sacrificial Conv. Sumitomo 1002-1003 202AR002/1 CLRLP1306H
1.000d 1.04 1 Thruster Brake for 250KW Reducer Sacrificial Conv. Sumitomo 1002-1004 202AR002/1 -
1.001 1.05 1 250 KW Motor Sacrificial Conv. Siemens 1002-1005 202AR002/1 CZAO-5013
1.000n 1.06 277 72" (1829mm) Conveyor Belt EP 1600/4 (Qty. in m) Sacrificial Conv. Phoenix 1002-1006 0220-CVB-0001-001 to -002 -
1.000n 1.07 2 Splice Kits Sacrificial Conv. Phoenix 1002-1007 202AR002/2 -
1.000b 1.08 1 Head Pulley Ø 914x2130 Face, w/ 19 Lagging, 2/ Ø Sacrificial Conv. RAS 1002-1008 202AR002/3 33593-A-ASM
202 Pillow Blocks
1.000b 1.09 1 Tail Pulley Ø 762x2130 Face, w/ 12 Lagging, 2/ Ø 202 Sacrificial Conv. RAS 1002-1009 202AR002/4 33593-C-ASM
Pillow Blocks
1.000f 1.1 3 Bend/ Take-UP Pulley Ø 762x2130 Face, w/ 12 Sacrificial Conv. RAS 1002-1010 202AR002/4 33593-C-ASM
Lagging, 2/ Ø 202 Pillow Blocks
1.000a 1.11 2 2.5° - 17.5° Adj. Idler, Ø152 Roll Sacrificial Conv. Lorbrand 1002-1011 202AR002/6 THY-ROB-ANT-7201
1.000a 1.12 3 17.5° - 32,5° Adj. Idler, Ø152 Roll Sacrificial Conv. Lorbrand 1002-1012 202AR002/7 THY-ROB-ANT-7202
1.000a 1.13 76 35° Troughing Idler, Ø152 Roll Sacrificial Conv. Lorbrand 1002-1013 202AR002/8 THY-ROB-ANT-7205
1.000a 1.14 4 35° Belt Scale Idler, Ø152 Roll Sacrificial Conv. Merrick Ind. 1002-1014 202AR002/9 IB105281
1.000a 1.15 8 35° Belt Scale Qualaty Idler, Ø152 Roll Sacrificial Conv. Lorbrand 1002-1015 202AR002/10 THY-ROB-ANT-7207
1.000a 1.16 32 35° Troughing Idler, Retractable Frame, Ø152 Roll Sacrificial Conv. Lorbrand 1002-1016 202AR002/11 THY-ROB-ANT-7204
1.17 2 Live Shaft 2/Ø75 Pillow Block, Ø300 Roll Sacrificial Conv. Lorbrand 1002-1017 202AR002/12 THY-ROB-ANT-7214
1.000a 1.18 1 Inverted Vee Return Idler, Ø194 Roll Sacrificial Conv. Lorbrand 1002-1018 202AR002/13 THY-ROB-ANT-7213
1.000a 1.19 13 15° Vee Return Idler, Ø194 Roll Sacrificial Conv. Lorbrand 1002-1019 202AR002/14 THY-ROB-ANT-7211
1.000a 1.2 21 15° Vee Return Idler, Low Drop, Ø194 Roll Sacrificial Conv. Lorbrand 1002-1020 202AR002/15 THY-ROB-ANT-7208
1.000a 1.21 2 Flat Return Idler, Ø194 Roll Sacrificial Conv. Lorbrand 1002-1021 202AR002/16 THY-ROB-ANT-7209
1.000a 1.22 8 55° Garland Impact Idler, Ø219 Roll Sacrificial Conv. Lorbrand 1002-1022 202AR002/17 THY-ROB-ANT-7203
1.000o 1.23 2 V-Plow 1830mm Wide Sacrificial Conv. Richwood 1002-1023 202AR002/20 D-6264 / 6266
1.24 7 Inspection Door 24"x24" Sacrificial Conv. PS Doors 1002-1024 202AR002/24 AH2424
1.25 64 Hood Cover, (Qty. in m) Sacrificial Conv. CAPOTEX 1002-1025 202AR002/26 THY-MAD-14
1.26 1 Belt Scale Module Sacrificial Conv. Merrick Ind. 1002-1026 202AR002/22 IB105281
1.27 1 Belt Scale Calibration Chain Sacrificial Conv. Merrick Ind. 1002-1027 202AR002/23 IB102817
1.28 1 Calibration Chain Winch Sacrificial Conv. Merrick Ind. 1002-1028 202AR002/23 IB104962
1.29 1 Belt Scale Over-Structure Mounting for Test Chain Sacrificial Conv. Merrick Ind. 1002-1029 202AR002/23 IB104962
Rack
1.3 280 6mm Wire Rope, Plastic Coated, (Qty. in m) Sacrificial Conv. TBD 1002-1030 202AR002/28 TBD
1.31 48 Wire Rope Clips Sacrificial Conv. TBD 1002-1031 202AR002/29 TBD
1.32 100 Pigtails 150mm Lg. w/ 2 Nuts Sacrificial Conv. AUSTDAC 1002-1032 202AR002/27 90-319-06
1.004 1.33 1 Metal Detector Sacrificial Conv. Advanced Detection 1002-1033 0220-ZMD-0005 D03710
System
1.000o 1.34 1 Primary Belt Scraper Sacrificial Conv. Richwood 1002-1034 202AR002/18 D-6247
1.000o 1.35 1 Secondary Belt Scraper Sacrificial Conv. Richwood 1002-1035 202AR002/19 D-6247
1.36 2 Manual Belt Reel Stands Sacrificial Conv. TKRI 1002-1036 202AR002/50 TBD
1.000l 1.37 2 Mechanical Belt Rip Hardware Sacrificial Conv. Conveyor 1002-1037 XS00514A1, XS00514A2 DB-100E
Page 142 Components
of 180
1.38 2 Inspection Door for Primary Cleaner 12"x12" Sacrificial Conv. PS Doors 1002-1038 202AR002/25 AH1212
BECHTEL / XSTRATA
ANTAPACCAY MINE
NUMBER
1 Inspection Door 18"x24" Sacrificial Conv. PS Doors 1002-1039 202AR002/26 AH1824
2.000 2 OVERLAND CONVEYOR 0220-CVB-0002

2.015 2.01 2 3800 KW Gearless Motor Overland Conv. Siemens 1002-2001 401AR002/1 0D5.0110-623429
2.000n 2.02 13320 54" (1372mm) Conveyor Belt ST 5000 (Qty. in m) Overland Conv. Phoenix 1002-2002 0220-CVB-0002-001 to -036 -
2.000l 2.03 1 Electronic Belt Rip Detector Overland Conv. Phoenix 1002-2003 XS00548 TBD
2.000l 2.04 1 Belt Rip Detection Loops Overland Conv. Phoenix 1002-2004 401AR002/2 TBD
2.000n 2.05 36 Splice Kits Overland Conv. Phoenix 1002-2005 401AR002/2 -
2.000b 2.06 1 Head Pulley Ø 1830x1670 Face, w/ 15 Plain Lagging, Overland Conv. RAS 1002-2006 401AR002/3 33593-D-ASM
2/ Ø 430 Pillow Blocks
2.000b 2.07 1 Bend Pulley Ø 1830x1670 Face, w/ 15 Plain Lagging, Overland Conv. RAS 1002-2007 401AR002/4 33593-D-ASM
2.000b 2.08 2 Drive Pulley Ø 1830x1670 Face, w/ 15 Ceramic Overland Conv. RAS 1002-2008 401AR002/5 34528-A-ASM
2.000b 2.09 1 Bend Pulley Ø 1220x1670 Face, w/ 15 Plain Lagging, Overland Conv. RAS 1002-2009 401AR002/6 33593-E-ASM
2.000b 2.1 8 Turn-Over Bend Pulley Ø 1000x1670 Face, w/ 15 Plain Overland Conv. RAS 1002-2010 401AR002/7 33593-F-ASM
2.000b 2.11 1 Bend Pulley Ø 1220x1670 Face, w/ 15 Plain Lagging, Overland Conv. RAS 1002-2011 401AR002/8 33593-E-ASM
2.000b 2.12 1 Tail Pulley Ø 1220x1670 Face, w/ 15 Heringbone Overland Conv. RAS 1002-2012 401AR002/9 33593-G-ASM
2.000b 2.13 1 Take-UP Pulley Ø 1220x1670 Face, w/ 15 Plain Overland Conv. RAS 1002-2013 400AR002/10 33593-E-ASM
2.000b 2.14 8 Turn-Over Live Rolls Ø 610x1670 Face, w/2 Ø 100 Overland Conv. Lorbrand 1002-2014 401AR002/11 LBP-00430
Pillow Blocks
2.000a 2.15 4 2.5° - 17.5° 3-Roll Adj. Transition Idler, Ø178 Roll, Overland Conv. Lorbrand 1002-2015 401AR002/12 THY-ROB-ANT-5405
Wide Base
2.000a 2.16 5 17.5° - 32.5° 3-Roll Adj. Transition Idler, Ø178 Roll, Overland Conv. Lorbrand 1002-2016 401AR002/13 THY-ROB-ANT-5406
Wide Base
2.000a 2.17 3134 35° 3-Roll Troughing Idler, Ø178 Roll, Wide Base Overland Conv. Lorbrand 1002-2017 401AR002/14 THY-ROB-ANT-5409
2.000a 2.18 2 35° 3-Roll Troughing Idler, Low Profile, Banking Overland Conv. Lorbrand 1002-2018-1 401AR002/15-1 THY-ROB-ANT-5410
Transition 1°, Ø178 Roll, Wide Base
2.000a 2.22 2 35° 3-Roll Troughing Idler, Low Profile, Banking Overland Conv. Lorbrand 1002-2018-0.5 401AR002/15-0.5 THY-ROB-ANT-5436
Transition 0.5°, Ø178 Roll, Wide Base
Transition 1.5°, Ø178 Roll, Wide Base Page 143 of 180
BECHTEL / XSTRATA
ANTAPACCAY MINE
NUMBER
2.000a 2.27 1479 35° 3-Roll Troughing Idler, Ø178 Roll, 5° Banking, Overland Conv. Lorbrand 1002-2019 401AR002/16 THY-ROB-ANT-5414
Wide Base
2.000a 2.28 17 35° 3-Roll Troughing Idler, Retractable Frame, Ø178 Overland Conv. Lorbrand 1002-2020 401AR002/17 THY-ROB-ANT-5408
Roll, Wide Base
2.000a 2.29 7 55° 5-Roll Garland Impact Idler, Ø219 Roll Overland Conv. Lorbrand 1002-2021 401AR002/18 THY-ROB-ANT-5407
2.000a 2.3 6 Flat 2-Roll Return Idler (Type Roll), Ø194 Roll, Wide Overland Conv. Lorbrand 1002-2022 401AR002/19 THY-ROB-ANT-5427
Base
2.000a 2.31 17 Flat 2-Roll Return Idler, Ø194 Roll, Wide Base Overland Conv. Lorbrand 1002-2023 401AR002/20 THY-ROB-ANT-5442
2.000a 2.32 913 20° 2-Roll Return Idler, Ø194 Roll, Wide Base Overland Conv. Lorbrand 1002-2024 401AR002/21 THY-ROB-ANT-5415
2.000a 2.33 16 20° 2-Roll Return Idler, Low Profile, Ø194 Roll, Wide Overland Conv. Lorbrand 1002-2025 401AR002/22 THY-ROB-ANT-5441
Base
2.000a 2.34 1 15° 2-Roll Inverted Vee Return Idler, Ø194 Roll, Wide Overland Conv. Lorbrand 1002-2026 401AR002/23 THY-ROB-ANT-5428
Base
2.35 3 Live Shaft Ø 300x1670 Face, w/2 Ø 90 Pillow Blocks Overland Conv. Lorbrand 1002-2027 401AR002/24 THY-ROB-ANT-5429
2.000a 2.36 8 20° 2-Roll Return Idler, Banking Transition 1° - 4°, Overland Conv. Lorbrand 1002-2028 401AR002/25 THY-ROB-ANT-5416-19
Ø194 Roll, Wide Base
2.000a 2.37 493 20° 2-Roll Return Idler, Banking 5°, Ø194 Roll, Wide Overland Conv. Lorbrand 1002-2029 401AR002/26 THY-ROB-ANT-5420
Base
2.000a 2.38 1 Flat Return Idler, w/Rubber Discs, Ø178 Roll, Wide Overland Conv. Lorbrand 1002-2030 401AR002/27 THY-ROB-ANT-5425
Base
2.000a 2.39 2 3° 2-Roll Return Idler, w/Rubber Discs, Ø178 Roll, Overland Conv. Lorbrand 1002-2031 401AR002/28-3 THY-ROB-ANT-5443
Wide Base
Wide Base
Wide Base
Wide Base
2.000a 2.43 71 15° 2-Roll Return Idler, w/Rubber Discs, Ø178 Roll, Overland Conv. Lorbrand 1002-2035 401AR002/29 THY-ROB-ANT-5424
Wide Base
2.000o 2.44 1 Primary Belt Scraper Overland Conv. Richwood 1002-2036 401AR002/30 1C-54
2.000o 2.45 1 Secondary Belt Scraper Overland Conv. Richwood 1002-2037 401AR002/31 1C-ITC-54
2.000o 2.46 6 V-Plow 1370mm Wide Belt Overland Conv. Richwood 1002-2038 401AR002/32 VP-SA-54
2.000u 2.47 1 Winch, Active for Take-UP Overland Conv. CONTINENTAL 1002-2039 401AR002/33 UD-26784
2.000u 2.48 1 Winch, Head Pulley Removal Overland Conv. TBD 1002-2040 401AR002/34 TBD
2.007 2.49 1 Maintenance Hoist, Head Pulley Removal Overland Conv. TBD 1002-2041 401AR002/91 TBD
2.000 2.5 2 Tail End Stopping Brake System with Disks Overland Conv. Svendborg 1002-2042 401AR002/35 490-4401-804
2.51 2 Flanged Coupling Ø 260mm OverlandPage
Conv.
144 RAS
of 180 1002-2043 401AR002/35 FC-026000
2.52 2 Head End Holding Brake System with Disks Overland Conv. Svendborg 1002-2044 401AR002/37 490-4400-801
BECHTEL / XSTRATA
ANTAPACCAY MINE
NUMBER
2.53 2 Flanged Coupling Ø 650mm Overland Conv. RAS 1002-2045 401AR002/37 FC-065000
2.006 2.54 6375 Hood Covers, (Qty. in m) Overland Conv. CAPOTEX 1002-2046 401AR002/38 THY-MAD-13
2.55 4 Wampfler Bumpers Overland Conv. Wampfler 1002-2047 401AR002/111 017111-160N
2.56 4 Wampfler Bumpers Overland Conv. Wampfler 1002-2048 401AR002/112 017111-200N
2.57 4 Load Runners Overland Conv. OSBORN 1002-2049 444MR002/1 TBD
2.58 4 Load Runners Shaft Overland Conv. OSBORN 1002-2050 444MR002/2 TBD
2.59 4 Wheel Block Overland Conv. Demag 1002-2051 477MR002/1 TBD
2.6 2 Mechanical Belt Rip Hardware Overland Conv. TKRI 1002-2052 432MR002/1 432MR002
2.61 1 Motorized Belt Reel Overland Conv. TKRI 1002-2053 401AR002/71 538MR002
2.62 1 3" ASTM A586 Class A, Grade 2 (MBS of 619 Tons) x Overland Conv. Mile High Rigging 1002-2054 401AR002/114 HS20920
+/- 171.98' (52.417 Meters) Long, 1" Galvanized
Structural Strand Assembly w/UF718 open Strand
Socket Zinc
2.63 1 3" ASTM A586 Class A, Grade 2 (MBS of 619 Tons) x Overland Conv. Mile High Rigging 1002-2055 401AR002/115 HS20920
+/- 87.10' (26.548 Meters) Long, 1" Galvanized
Structural Strand Assembly w/UF718 open Strand
Socket Zinc
2.64 1 2-3/4" ASTM A586 Class A, Grade 2 (MBS of 520 Overland Conv. Mile High Rigging 1002-2056 401AR002/116 HS20920
Tons) x +/- 135.26' (41.228 Meters) Long, 1.5"
Galvanized Structural Strand Assembly w/UF717 open
Strand Socket Zinc
Tons) x +/- 83.99' (25.999 Meters) Long, 1" Galvanized
Structural Strand Assembly 2/UF709 open Strand
Socket Zinc
Tons) x +/- 135.96' (41.440 Meters) Long, 1"
Galvanized Structural Strand Assembly w/UF708 open
Strand Socket Zinc
2.67 22 Ladder Safety Gate Model No. LSG-24-PCY Overland Conv. PS Doors 1002-2059 401AR002/120 TBD
2.68 3 Inspection Door 24"x24" Overland Conv. PS Doors 1002-2060 401AR002/122 AH2424
2.69 1 Inspection Door 12"x12" Overland Conv. PS Doors 1002-2061 401AR002/123 AH1212
Page 145 of 180

Table of Contents
3 MAINTENANCE
3 MAINTENANCE
3.1 OPERATING & MAINTENANCE MANUAL 150

3.2 SPARE PARTS 182
3.3 LUBRICATION REQUREMENTS 183
Table of Contents 3 Maintenance

ThyssenKruppRobins
Operating
and
Maintenance
Manual
ANTAPACCAY PROJECT - TINTAYA EXPANSION

CONVEYING SYSTEM
Table of Contents:
I) General Section
II) Section relating to machine type
III) Section relating to machine ordered
IV) Local Section
PD, 05.11.2003 Operating and Maintenance Manual


ThyssenKruppRobins
I) General Section
1. General
1.1 Users guide 148

1.2 Liability and warranty 150
1.3 Copyright 150
1.4 Technical modifications 150
2. General safety instructions
2.1 Principles 151

2.2 Modifications and spare parts 152
2.3 Personnel 152
2.4 Noise pollution 155
2.5 Residual risks during daily operation 155
2.6 Disposal of consumables and process materials 155
2.7 Fire protection 156
2.8 Post Earthquake Evaluation 158
2.9 Designated use 159
3. General Operating instructions
3.1 General information 160

3.2 Equipment testing 160
3.3 No-Load Commissioning of the System 160
3.4 Safety instructions relating to operation 161
4. General Maintenance Principles
4.1 Safety instructions relating to maintenance 163

4.2 Inspection 166
4.3 Maintenance 168
4.3.1 Cleaning instruction 169
4.3.2 Lubrication instructions 171
4.3.3 Instructions relating to oil hydraulic system 172
4.3.4 Instructions for the replacement of wear parts 174
4.4 Repair 176
4.5 Spare part stocks 177


ThyssenKruppRobins
I) General Section
1 General
1.1 Users guide
The technical documentation (manual) is designed to familiarize the user

with the machine/plant and its intended use.
This manual has been prepared by ThyssenKrupp Robins and must be

observed in every detail by those responsible for the transport, assembly,
commissioning, operation and maintenance of the machine/plant, as well as
the disposal of all consumables and process materials. Only by following the
instructions in this manual can errors be avoided in operating and servicing
the machine/plant, thus ensuring trouble free operation.
The manual contains important information on how to operate the

machine/plant safely, properly and most efficiently. Observing this
information helps to avoid danger, reduce repair costs and downtimes and
increase both the reliability and the life of the machine/plant.
The operation and maintenance manual must always be available, wherever

the machine/plant is in use.
The descriptions contained in the manual are given on the assumption that
only skilled personnel who have received adequate training will be
employed in operation the machine/plant.
The manual does not include instructions and guidelines for major repair
work. ThyssenKrupp Robins can provide skilled and qualified personnel to
carry out inspections and repairs if required
The manual includes numerous instructions for accident prevention.

However, the user is responsible for training the operating staff on site and
ensuring that the safety regulations are complied with.
The operating manual refers to various types of warnings, each consisting

of a symbol and text. The design of the warning varies depending on the
type, nature and severity of the hazard.


ThyssenKruppRobins
The following symbols and designations are used in the manual to highlight
instructions of particular importance:
Danger!
This draws attention to risks/hazards which may occur with the activities
described. In case of “Danger” reference is made to hazards or
circumstances which could cause injury to persons. If you expose yourself
or other people to this risk, death or severe injury may be the consequence.
Adhere strictly to the safety regulations and proceed with the utmost care.
Caution!
This draws attention to risks may occur with the activities described. In case
of “Caution” reference is made to activities which could cause damage to
the machine/plant or other objects.
Note!
Includes additional information and tips for operating the machine/plant
skilfully and economically.
Definitions:
Right = on the right-hand side looking in conveying direction
Left = on the left-hand side looking in conveying direction
• = instructions (in stated order)
- = listing in text
/ = or


ThyssenKruppRobins
1.2 Liability and warranty
ThyssenKrupp Robins explicitly exclude all liability and warranty claims for
damage or operational malfunctions caused by:
• Disregarding any information / instructions included in the manual,
• incorrect operation
• any use of the machine other than the designated use,
• insufficient servicing
• use of consumables (particularly lubricants) not explicitly approved

by the manufacturer,
• use of spare parts not approved by the manufacturer
• conversions and modifications not approved by the manufacturer
• The contractually agreed warranty and liability provisions for the

supply of the machine/plant remain applicable.
1.3 Copyright
ThyssenKrupp Robins reserve all rights in connection with this

documentation, including those relating to patent registration or utility-model
registration. Without our previous written consent, this documentation may
neither be disclosed to third parties nor be reproduced without our
permission nor be used in any other unauthorized manner.
1.4 Technical modifications
ThyssenKrupp Robins reserve the right to change designs as a result of

technical developments. Recent modifications may not yet have been
included in the drawings and texts of this manual.


ThyssenKruppRobins
2 General safety instructions
2.1 Principles
The machine/plant has been manufactured in accordance with state-of- the-

art standards and recognized safety rules. Nevertheless its use may
constitute a risk to life and limb of the user or third parties, or cause damage
to the machine/plant and to other material property.
These safety instructions must be observed by all persons responsible for

the transport, assembly, commissioning, operation and maintenance of the
machine/plant, as well as the disposal of consumables and process
materials. We recommend that the owner obtains signed confirmation that
the safety instructions have been read and understood by his personnel.
The machine/plant must only be used in a perfect technical condition in

accordance with its designated use and the instructions set out in the
manual, and only by safety-conscious persons who are fully aware of the
risks involved in operating the machine/plant. Any functional disorders,
especially those affecting the safety of the machine/plant, should therefore
be rectified immediately.
In addition to the operating manual, all other generally applicable legal and
mandatory regulations relating to accident prevention and environmental
protection must be observed.
If required on site, the user may draw up, at his responsibility, additional
instructions for the operation and maintenance of the machine/plant, in
consultation with the local authorities and according to the local laws and
regulations.
These compulsory regulations may also deal with the handling of hazardous
substances and wearing of personal protective gear.
Observe all safety instructions and warning signs attached to the

machine/plant.
Ensure that safety instructions and warning signs attached to the

machine/plant are always complete and perfectly legible.


ThyssenKruppRobins
In the event of safety-relevant modifications or changes in the behaviour of

the machine/plant during operation, stop the machine/plant immediately and
report the malfunction to the responsible person.
Never make any modifications, additions or conversions to the

machine/plant which might affect safety without the supplier’s approval. This
also applies to the installation and adjustment of safety devices and valves
as well as to welding work on load-bearing elements.
Replace hydraulic hoses within stipulated and appropriate intervals even if

no safety-relevant defects have been detected.
Adhere to prescribed intervals or those specified in the operating and

maintenance manual for routine checks and inspections.
When carrying out maintenance work only use tools and workshop
equipment suitable for the task in hand.
Measures must be taken to guarantee that the machine is only operated in a

safe and fully operational condition. Do not operate the machine unless all
safety devices and facilities are correctly installed and are fully operational.
These operation and maintenance instructions must be supplemented by

instructions covering the duties involved in supervising and notifying special
internal company features such as job organization and working sequences.
2.2 Modifications and spare parts
For safety reasons, conversions and modifications are prohibited unless

previously approved by ThyssenKrupp Robins.
The use of accessories and spare parts not approved by ThyssenKrupp

Robins may cause unforeseeable hazards.
2.3 Personnel
It is prohibited to drink alcohol and take drugs before and during working
hours.


ThyssenKruppRobins
Personnel entrusted with work on the machine/plant must have read the
manual and in particular the chapter on safety before beginning work.
Reading the instructions after work has begun is too late. This applies
especially to persons working only occasionally on the machine/plant, e.g.
during setting up or maintenance.
Only persons wearing the statutory protective clothing may access the
machine/plant. Personnel must, at the very least, wear a hard hat, safety
glasses and safety shoes.
For safety reasons, long hair must be tied back or otherwise secured,
garments must be close-fitting and jewellery - such as rings – must not be
worn. Injury may result from getting up in the machinery or from rings
catching on moving parts.
Use protective equipment wherever required by the circumstances or by

law.
Protective clothing
Hard hat
Safety shoes
Protective gloves
Safety glasses / Protective goggles
Familiarize all personnel with all safety devices and warning signals before


ThyssenKruppRobins
allowing access to the machine. The operating personnel must be familiar

with the location of the emergency-stop switches.
Danger!
Operators must be familiar with all safety regulations and safety devices in
order to react immediately in case of emergency. The user is responsible for
training his staff accordingly and to keep the training standards at a high
level. Safety regulations and safety devices must be checked regularly and
must not be rendered inoperative.
Any work on and with the machine/plant must be carried out only by reliable
personnel who are able to carry out the job both physically and mentally.
Statutory minimum age limits must be observed.
Employ only trained or instructed staff and set out clearly the individual
responsibilities of the personnel for operation, set-up, maintenance and
repair.
With regard to staff, this manual distinguishes between:
• Operating personnel with the exclusive task of operating the

machine
• Maintenance personnel entrusted with maintenance, inspection and

repair duties, which include cleaning and lubricating parts of the
machine/plant, as well as the replacement of spare and wear parts,
the disassembly and assembly of components and all kinds of repair
work.
• Supervisory personnel responsible for giving the appropriate

directions in connection with the work that is to be carried out and for
supervising any such work.
Define the machine operator’s responsibilities - also with regard to

observing traffic regulations - giving the operator the authority to refuse
instructions by third parties that are contrary to safety.
Work on the electrical system and equipment of the machine/plant must be

carried out only by a skilled electrician or by instructed persons under
the supervision and guidance of a skilled electrician and in accordance with


ThyssenKruppRobins
electrical engineering rules and regulations applicable or valid at the place

of operation.
Work on the safety related controls of the machine/plant may only be carried
out by specially trained personnel.
Work on the hydraulic system must be carried out only by personnel with
specialist knowledge and experience of hydraulic equipment.
Persons being trained or instructed, or persons taking part in a general

training course may only work on the machine/plant under the supervision of
an experienced person.
2.4 Noise pollution
(Job-related emission value)
Depending on the intended use of the machine/plant, noise emissions occur

which can only be measured during operation. Immediately after
commissioning the user has to ensure that, according to local regulations,
the noise level is measured at all operating positions (e.g. for maintenance
and inspection, control station).
When the permissible limits are exceeded, the operating personnel must
wear protective equipment such as ear protectors.
2.5 Residual risks during daily operation
The machine has been designed taking into account the contractually
agreed safety requirements.
However, risks may nevertheless occur during machine/plant operation.
Its use may constitute a risk:
• to the life and limb of the user’s operating/servicing personnel, or
• to third parties, or


ThyssenKruppRobins
• cause damage to the plant or to other material property.
Section II) of this manual refers to the typical hazards of the machine/plant
in operation which cannot be prevented even if all safety regulations have
been observed.
2.6 Disposal of consumables and process materials
Ensure that all consumables and process materials are disposed of properly
with no environmental impact. All applicable national regulations for the
protection of the environment must be complied with.
2.7 Fire Protection
Observe the legal regulations governing fire protection and prevention and
supplement them with the company’s own instructions. Consult the
insurance company’s fire experts for this purpose.
Appoint supervisory personnel responsible for all matters concerning fire

prevention and fire fighting and provide them with the necessary authority.
Managerial staff and engineers must give the appropriate advisory support.
The supervisors must inspect the fire fighting equipment and installations at
regular intervals to ensure that they are always ready for use. Particular
attention must be paid to areas which can easily catch fire.
Personnel entrusted with supervisory and fire-fighting tasks must have

attended first-aid courses. First-aid points must be provided.
Display the fire protection rules at several points on the plant.
All personnel must receive instruction in fire protection measures. Fires

must be reported immediately.
The assembly units and assembly groups which heat up during operation
due to the electrical and/or mechanical load, to which they are subjected,
must be monitored by the staff responsible for this equipment. This applies,
for example, to blowers, gear units, bearings, motors, oil lubrication and


ThyssenKruppRobins
hydraulic systems.
The user must provide an adequate number of hand-held fire-extinguishers

at easily accessible places. Fire extinguishers must be easily accessible
and must not be hidden behind other objects.
Personnel must be familiarized with the use of fire extinguishers so that they
can fight fires using the type of extinguishers suitable for the particular fire.
The operating, maintenance and servicing personnel must be trained to

watch out for potentially dangerous fire situations, to report them and, if
necessary, to eliminate them.
This manual is not a fire-prevention instruction. The user is responsible for

adhering to the national, state and local regulations in consultation with the
local authorities.
We recommend that the following procedures be adopted:
• Use water on burning wood, rubbish, fabrics, jute, paper, belts etc.
• Always use CO2 or dry (powder) extinguishers on burning liquids

(mineral oil, petrol, oil, paint, tar etc.
• Always use CO2 or dry (powder) extinguishers on burning cables,

motors, electrical equipment etc.


ThyssenKruppRobins
2.8 Post Earthquake Evaluation
Earthquakes, even at low intensity, may damage the structure of the

machine/plant. Therefore, after each earthquake, an extensive inspection of
the machine/plant according to the recommendations specified in this
manual and the local applicable specifications must be carried out.
All structures are designed according to the contractually predetermined

earthquake intensity.
Any inspection plan to be prepared by the user must be based on national

specific standards, guidelines and laws. Recommendations specified herein
have to be integrated into the overall plan of the user.
This plan shall include:
• the organisation of the inspection team
• a list of risks for the machines and structures sorted by priorities.
The inspection team shall consist of structural engineers and/or design

engineers experienced in the design of structures exposed to earthquakes.
A detailed inspection and valuation of the structures and machines shall be
carried out. Personnel experienced in maintenance and operation shall
carry out an inspection and valuation of the mechanical and electrical
system as well as the control system of the machine.
It is necessary that the inspection team has an inspection list arranged

according to priority of danger.
For inspection and valuation of damage the priority shall be specified as

follows:
• First priority:
damage to the supporting structure anchors and foundations
including foundation settlement
• Second priority:
operational related damage.


ThyssenKruppRobins
The scope of the inspection shall be consistent with the intensity of the
earthquake:
• minor earthquakes:
inspection for misalignment
• moderate earthquakes:
damage may occur both in the linings and claddings as well as to the
utility service lines. Misalignments due to foundation movement are
also possible.
• strong earthquakes:
damage to the supporting structure and the mechanism may occur.
Inspection of all supporting elements and mechanical components is
necessary.
In case of doubt after a minor earthquake, it would be better to carry out a

complete inspection in order to find, at early stage, even minor damage that
may lead to consequential damage.
2.9 Designated use of the machine/plant
Only use the machine/plant within the limits of its designated use, which are
specified in the contract of supply for the machine/plant. ThyssenKrupp
Robins cannot be held liable for any damage resulting from any misuse. The
risk of such misuse lies entirely with the user.
Operating the machine/plant within the limits of its designated use also
involves observing the instructions set out in the operating manual and
complying with the maintenance directives.
Caution!
Only operate the machine/plant in its original condition and only use spare
and wear parts supplied or approved by TKRI.
Modifications must be carried out by TKRI or be technically approved by

TKRI. TKRI cannot be held liable for damage resulting from spare parts or
wear parts delivered by third parties or for modifications that have not been
carried out or approved by TKRI.


ThyssenKruppRobins
3. General Operating Instructions
3.1 General Information
We strongly recommended that the assistance of TKRI staff is sought for

the initial start-up process, not only for warranty reasons, but also for:
• inspecting the machine/plant
• determining the optimum performance
• instructing the operating staff
• giving additional information on the mode of operation, maintenance

and repair.
3.2 Equipment Testing
Before the equipment is powered, all checks and tests which can be carried
out should be completed including:
• Compliance with applicable codes, standards, specifications ,

drawings and manuals
• Checking the tightening torques of HSFG bolts
• Checking all piping and hydraulic systems for leaks.
• Checking the adjustment torques of couplings and brakes
• Checking the brake settings (if any).
• Ensure the correct fluid level in all gearboxes, fluid couplings etc.
• Ensure all equipment is lubricated in accordance with the

manufacturer’s specification.
• Ensure all moving parts are properly protected.
• Complete a functional check on all safety devices and emergency

stops.
• Complete a general visual inspection for any obvious damage.


ThyssenKruppRobins
3.3 No-Load Commissioning of the System
Prior to and during no-load commissioning of the System, the following

instructions, which are the responsibility of the supervisory staff, must be
followed:
• All technical and operational safety rules and regulations have been
established, and must be complied with.
• All operating personnel must know the location of all emergency

shutdown switches and all local control switches.
• The System must have been inspected, and foreign materials etc.
removed.
• The System must be operated without load first, in order to confirm

the proper functioning of components.
3.4 Safety Instructions relating to the operation
Keep a log book in which the following information is recorded on a daily

basis:
• Starting and finishing times of work
• Responsible equipment operator and responsible supervisory

personnel of the machine/plant
• Material throughput
• Downtimes and reasons
• Maintenance and repair work carried out, including the name of the
person(s) carrying out the work
• Unusual occurrences
Organize shift changes so that the shifts overlap. This ensures that all
important information, in addition to that entered in the log book, is passed
on.
Operate the machine/plant only if all protective and safety-oriented devices

such as removable guards and emergency shutdown equipment, sound-
proofing elements and exhausters are in place and fully operational.


ThyssenKruppRobins
It is strictly forbidden to pass under moving or rotating plant parts. Do

not touch moving or rotating parts.
When working at or with the machine, always wear the specified protective
gear.
Any possible sources of ignition, such as sparks, current leakage,

overheating, etc. must be avoided.
All braking systems must be checked to ensure that they are in perfect
working order.
Check the machine/plant at least once per working shift for obvious damage
and defects. Report any changes (including changes in the machine’s
working behaviour) to the responsible person immediately. If necessary,
shut the machine/plant down immediately and lock it.
Repair any malfunctions immediately.
During the start-up and shutdown procedures always watch the indicator
instruments/displays in accordance with the manual!
Frequent starting and shutdown operations may affect the machine.
Before starting up the machine/plant, make sure that no-one is at risk.
GIVE WARNING SIGNALS!


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4 General maintenance principles
Servicing work is intended to maintain and restore the required condition of

the machine/plant, as well as to determine and assess its current condition.
Servicing work comprises

• maintenance
• inspection
• repair
Repair work must be carried out on schedule in accordance with the

specified scope of work.
4.1 Safety instructions relating to maintenance
Danger!
Do not carry out cleaning, inspection and maintenance work unless the
machine/plant is shut down.
Caution!
For the safety of the machine and for your own safety all maintenance work
must be carried out on time. Do not postpone maintenance work. The
manufacturer does not accept liability for damage resulting from
maintenance work that is not carried out or has not been carried out on
time.
Observe the adjusting, maintenance and inspection activities and intervals

set out in the manual, including information on the replacement of parts and
equipment. Only skilled personnel are allowed to carry out the work.
Brief operating personnel before beginning maintenance work, and appoint

a person to supervise the activities.
In any work concerning the operation, conversion or adjustment of the

machine/plant and its safety-oriented devices or any work related to
maintenance, inspection and repair, always observe the start-up and
shutdown procedures set out in the manual and the information on


ThyssenKruppRobins
maintenance work.
Do not carry out work on the machine/plant unless it is shut down.
If the machine/plant is completely shut down for maintenance and repair

work, it must be secured against inadvertent starting by:
Locking the principal control elements and removing the key and/or
attaching a warning sign to the main switch.
Before restarting the machine/plant after repair work, check that all safety
devices are fitted and in working order.
After electrical assembly or repair work is completed, check the protection

system (e.g. earth resistance).
To avoid the risk of accidents, individual parts and large assemblies being
moved for replacement purposes should be carefully attached to lifting
tackle and secured. Use only suitable and technically perfect lifting gear and
suspension systems with adequate lifting capacity. Never work or stand
under suspended loads.
Loads must be fastened and crane operators instructed by experienced

persons only. The foreman giving the instructions must be within sight or
sound of the operator.
For carrying out overhead assembly work always use specially designed
safety-oriented ladders and working platforms. Never use machine parts as
a climbing aid. Wear a safety harness when carrying out maintenance work
at heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from
dirt, snow and ice.
Always tighten up any bolted connections that have been loosened during
maintenance and repair work.


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Any safety devices removed for set-up, maintenance or repair purposes

must be refitted and checked immediately upon completion of the
maintenance and repair work.
Ensure that all consumables and replaced parts are disposed of safely and
ecologically.
Use only original fuses with the specified current rating. Shut down the
machine/plant immediately when faults occur in the electrical system.
Work on the electrical system or equipment may only be carried out by a

skilled electrician or by specially instructed personnel under the control and
supervision of a skilled electrician and in accordance with the applicable
electrical engineering rules.
If provided for in the regulations, the power supply to parts of machines and
plants on which inspection, maintenance and repair work is to be carried out
must be cut off. Before starting any work, check that the shutdown parts are
de-energized and connect to earth or short-circuit them in addition to
insulating adjacent live parts and elements.
The electrical equipment of the machine/plant is to be inspected and

checked at regular intervals. Defects such as loose connections or scorched
cables must be rectified immediately.
Necessary work on live parts and elements must be carried out only in the
presence of another person who can cut off the power supply in case of
danger by actuating the emergency stop or main power switches. Cordon
off the working area with a red-and-white safety chain and set up a warning
sign. Use insulated tools only.
Before starting work on high-voltage assemblies and after cutting off the
power supply, the supply cable must be connected to earth and
components, such as capacitors, short-circuited with an earth rod.
Carry out welding, flame-cutting and grinding work on the machine/plant

only if this has been expressly authorized, as there may be a risk of
explosion and fire.


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Before carrying out welding, flame-cutting and grinding operations clean the
machine/plant and its surroundings from dust and other inflammable
substances and make sure that the premises are adequately ventilated (risk
of explosion).
Check all lines, hoses and bolted connections regularly for leaks and
obvious damage. Repair damage immediately. Splashed oil may cause
injury and fire.
Depressurize all system sections and pressure pipes to be removed in

accordance with the specific instructions for the unit concerned before
carrying out any repair work.
Hydraulic lines must be routed and fitted properly.

Ensure that connections are not mixed up. The fittings, lengths and quality
of the hoses must comply with the technical requirements.
When handling oil, grease and other chemical substances observe the
product-related safety regulations.
Be careful when handling hot consumables. There is a risk of burning or

scalding.
4.2 Inspection
Caution!
Inspection is intended to recognize well in advance any essential repair
works in order to be able to make the necessary preparation and to carry
out the work. Check the plant at least once per shift for obvious damage
and defects. Report any changes (including changes in the machine’s
working behaviour) to the responsible person immediately.
In the event of malfunctions, stop the machine/plant immediately and lock it.
Have any defects rectified immediately.


ThyssenKruppRobins
Recommendations for General Supervision of Machinery Condition.
Machinery and equipment should not continue to be operated until they fail
completely. Monitoring the condition of the equipment is quite simple. Four
techniques are commonly used to monitor the condition of the equipment
which is sophisticated, portable and always available. They are the four
senses: touch, hearing, smell and sight.
These four senses can recognize:
1) Any increases or decreases in temperature (touch and smell).
2) Any increases or decreases in vibration (touch).
3) Any change in noise or sound from the machine (hearing).
4) Any visual or observed changes and problems (sight).
Each technique helps in determining to what extent a mechanical fault

exists and if it is increasing.
Temperature
Bearing temperatures can be roughly felt by touching them with a hand.

Overheating is often first detected by smell coming from hot plastics or oil.
Higher temperatures often indicate that a bearing is acting abnormally. Too

high temperature can be detrimental to the bearing, lubricant, shaft and
seals.
Causes of high bearing and lubrication temperatures can be insufficient or

excessive lubrication, contaminated lubricants, overloading, bearing
damage, faulty installation, insufficient bearing clearances, and improper or
failed seals.
Check the temperature of bearings periodically. Any significant change in

temperature is usually a good indication that a problem exists, especially if
the operating conditions of the machine have not been altered.
Danger!
Bearings, couplings, brakes, gear units, electric motors, engines and their
components may become so hot that you risk being burnt when touching
them.
Vibration
Another method commonly used to “feel” the condition of a machine is to
determine how much vibration exists on the machine. By touching the
bearing, high temperature and vibrations can be felt. The amount of
vibration cannot be measured this way, but it can be compared with the


ThyssenKruppRobins
vibrations from yesterday or several weeks ago.
Listening
Another method used to identify irregularities on machinery and equipment
is to listen for changes in sounds coming from machines while operating
under normal load and speed conditions. This can be done by placing a
screwdriver blade on the bearing housing and, in a safe position, allowing
your ear to touch the screwdriver handle and listen to the internal sounds
coming from the bearing. Abnormal noises may be detected and traced to a
specific component of the machine by experienced maintenance personnel.
Grinding, squeaking and other irregular sounds can point to worn bearings.
The squeaking noise is often caused by inadequate lubrication. Insufficient
bearing clearances can make a metallic sound. Indentations in the outer
ring raceway will produce smooth, clear sounds, and ring damage caused
by shock loads or hammer blows lead to sounds varying in frequency
according to the operating speed of the machine. Intermittent noises
probably indicate damage to the rotating members. Contamination in the
bearing produces a rough grinding sound. Damaged bearings produce
irregular and loud noises. Good bearings run smoothly and produce a
constant humming sound.
Sight
Maintenance personnel can simply observe the equipment to see if there is
anything out of the ordinary happening.
Check for any apparent oil leaks or grease leaks around seal areas or if any
of the bearing housings are loose, cracked or improperly assembled. Check
the lubricant. Discoloration or darkening of the oil is usually a good
indication that the lubricant is either contaminated or worn out. It is also very
important to check whether there is sufficient lubricant. Is the lubricant the
proper one for the application? Check whether the air vent is free from
obstructions.
Take a small sample of used oil and compare it with new oil. If the used oil
is cloudy in appearance, water has more than likely mixed with it, therefore,
the oil must be replaced.
Dark or thick oil is a sure sign of contamination or that the oil has started to
carbonise.
Overheating may have caused this problem.
4.3 Maintenance
It is important that maintenance is performed only by well-trained and

competent personnel. Trained and skilled personnel are able to recognize
malfunctions before they occur and to take the necessary preventive


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measures.
Malfunctions caused by inadequate or improper maintenance may result in

high repair costs and long downtimes. Therefore, regular maintenance is a
must.
The functional safety, disruption-free operation and service life of the

machine/plant all depend on proper cleaning, inspection and servicing.
Check the machine/plant at the specified intervals (inspection intervals,

servicing intervals) for proper operation, state of lubrication and wear.
Replace or repair all damaged/worn parts.
Check the paintwork at regular intervals (period depends on operating

place) for corrosion. Properly touch up all damaged areas.
Have all instrumentation and control devices/electrical interlocks checked

for proper functioning at regular intervals by qualified personnel.
Note!
Periods when the plant is shut down for repairs must also be used for
scheduled servicing work.
Different operating conditions necessitate wear tests, inspections,

maintenance and repairs to be carried out at different intervals. A suitable
routine inspection schedule has to be prepared in accordance with the
operating conditions.
The servicing table (section II) is a guideline for inspection and maintenance
work.
Danger!
For maintenance and repair work strictly follow the general safety
instructions included in section III.)


ThyssenKruppRobins
Note!
For lubricating the machine/plant please refer to section III.)
As recommended for the initial start-up, you are advised to have repairs
carried out by ThyssenKrupp Robins staff the first time. In that way, your
maintenance staff will have the opportunity of taking part in an intensive
training course.
4.3.1 Cleaning instructions
Check the level of contamination of the machine/plant every day. Do not

allow material to accumulate or cake. This may disrupt the operation of the
mechanical plant parts and increase the level of wear.
Danger!
Danger! Do not carry out cleaning, servicing or repair work unless the
machine is shut down. Secure the system against inadvertent restarting.
Only use appropriate tools in perfect condition.
Always clean the assembly groups in question before commencing

servicing work.
Before cleaning the machine/plant with water or steam (high-pressure

steam jet cleaners) or other detergents, cover/tape up all openings in
which water/steam/detergents are not allowed to penetrate for safety and/or
operational reasons. Electric motors and control cabinets are particularly
susceptible to moisture.
Danger!
Always wear safety masks when carrying out cleaning work with high-
pressure or steam jet cleaners.


ThyssenKruppRobins
Do not use aggressive detergents.
Do not direct the spraying jet at electrical devices, relays and control
cabinets/boxes, intake filters and ventilation filters or greased surfaces.
Always hold the spray nozzle at an adequate distance from the surface
being cleaned and do not direct the spray jet directly at these surfaces.
Clean places which are difficult to reach with suitable equipment such as
special brushes.
When cleaning is completed, completely remove the covers/tapes.
After cleaning check all lubricant and hydraulic oil lines for leaks, loose
fittings, scouring and damage. Immediately rectify or repair any defects.
4.3.2 Lubricating instructions
In order to maintain the operational reliability and achieve an adequate

service life of the machine/plant, it is essential to use lubricants most
suitable for the individual application. It is not possible to fully describe the
lubricants, simply by providing the guide values indicated in the table of
lubricants. The responsibility for the correct choice of the lubricants - taking
into account the local circumstances and working conditions in industrial
plants as well as the latest developments of lubrication technology - lies
exclusively with the lubricant supplier.
TKRI cannot be held liable for defects or damage resulting from the use of
unsuitable or improper lubricants.
It is therefore recommended that only high-quality lubricants from reputed

firms which meet our guide values are used.
Special attention must be paid to the following:


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Danger!
• For safety reasons, all work in connection with lubrication must be
carried out only with the machine/plant shut down and at operating
temperature.
• Carry out lubrication in accordance with the lubricating instructions

(section II) specifying the lubrication intervals, the kind of lubricants
to be used and the quantities. Insufficient lubrication may cause
damage to the machine parts.
• For recommended lubricants please refer to the table of lubricants

(section 3).
This guideline does not exclude the use of lubricants with the same
properties but of another make. However, do not mix lubricants.
Storage of lubricants:
• Store lubricants such as oil and grease in clean, closed containers

(tins, cans, barrels, etc.) to keep them clean and dry.
• Containers must be labelled differently, possibly using different

colors according to their different content. Containers must be closed
immediately after removing the required amount of oil or grease.
• Consumables must be ecologically stored in a safe place.
• Keep the lubricants in a dry, cool place.
• Please note the respective national regulations for environmental

protection.
4.3.3 Instructions relating to oil hydraulic system
Reliable operation of oil hydraulic systems primarily depends on proper

maintenance.
It is impossible to specify exact maintenance intervals. The correct

maintenance intervals are a matter of experience. The only thing that is
important is that maintenance is carried out regularly.


ThyssenKruppRobins
Caution!
On the basis of the existing safety regulations, persons not directly required
for operating the plant have to leave the site or keep well away from the
plant when it is commissioned.
The general instructions given below may occasionally be superseded by

special instructions:
• When the machine/plant is assembled, care must be taken that

everything is kept absolutely clean.
• Pipes must be cut square. The use of cutting rollers is prohibited.

Note special instructions applying to pipe welding.
• When welding is carried out, care must be taken to prevent welding

current from flowing through any hydraulic appliance to avoid
welding of internal parts.
• Pipes must be cleaned prior to installation.
• Pipes must be installed free of strain.
• Sealing with hemp and putty is not permitted.
• Pump suction lines must be carefully sealed to prevent air from

being taken in. Leakage oil lines must be installed to ensure that the
pumps and motor casings always remain filled with oil; they must not
be connected to pressure and drain lines.
• Before filling the liquid, tanks and pipes must be flushed, subjected
to a pressure test and checked once again to see if they are clean.
• It is therefore highly recommended to carefully check the piping and

wiring on the basis of the circuit diagram before filling the hydraulic
fluid into the tank.)
• Solenoid valves and pressure switches must be checked with

respect to the type of current and voltage.
• Pumps and their motors must be aligned. Possible misalignment

between the motor and the pump may cause the pump to fail
prematurely. The operation of the pumps and their motors must not
be impaired by an improper installation and connection of pipes.
• If not already delivered in a ready-for-operation state, accumulators


ThyssenKruppRobins
must be provided with the specified nitrogen charge before being

incorporated into the system. It is advisable to mark the gas pre-
pressure on the accumulator itself (e.g. using a sticker) and also in
the circuit diagram to allow future comparative checks to be carried
out if necessary.
• ISO VG oil selected to meet the respective climatic conditions and/or

ambient temperatures must be used. The hydraulic oil must always
be filtered during filling.
• Prior to their initial start-up, the pumps and motors must be filled
through the leakage oil port.
• During start-up the pressure settings of the pressure relief valves

must be kept low at first, except for the type-tested pressure relief
valves for hydraulic systems which do not allow for any variation
because of their predetermined and leaded fixed-value setting.
• Cylinders must be installed without strain. They must not be subject

to transverse forces as this may cause malfunctions and premature
wear.
• The fluid level must be checked constantly during commissioning.

When the plant has been commissioned, check the fluid level every
day at first and every week later on.
• During commissioning and the first hours of operating, filters must be

checked frequently, and, if necessary, changed.
• In case optical or electrical clogging indicators are available, filter

elements must be replaced as indicated.
• Breathers must be checked at regular intervals and the filter

cartridge be replaced, if necessary.
• The operating temperature must be measured not only in the oil tank
but also at the bearing points of the pumps. A temperature rise
indicates wear (growing friction and leakage by converting hydraulic
energy into heat).
• The frequency of changing system fluids depends on several

operating factors and is governed by the degree of ageing and
pollution. Regular laboratory tests of the hydraulic oil must be carried
out especially in case of large oil quantities.
• The preliminary pressure on the nitrogen side of accumulators must

be checked at regular intervals if necessary. Do not check unless the
oil side of the accumulators is completely depressurized.


ThyssenKruppRobins
• It is recommended to check at regular intervals the correct alignment

of the energy converters (pumps, motors, cylinders etc.) at operating
temperature and, if possible, under operating pressure. This includes
attachment bolts, screws, connections, pipes, couplings, etc.
• The hydraulic piping system must be checked for leaks at regular

intervals. Do not tighten up bolted connections unless the system is
depressurized.
• Depending on the environmental conditions, disks of oil/air coolers

must be cleaned at regular intervals.
• Decalcify oil/water coolers from time to time.
• The frequency depends on the hardness of the cooling water used.
• Store pumps, valves, cylinders etc. in a dry place away from moist
air.
• The storage rooms must be free from caustic materials and vapours.
A fill of anticorrosive oil is recommended. This oil must be compatible
with the future oil grade. The oil film remaining after draining the
anticorrosive oil must not affect future use.
4.3.4 Instructions relating for the replacement of wear parts
Danger!
Note the safety instructions relating to maintenance (section 1).
To avoid the risk of accidents, individual parts and large assemblies being
moved for replacement purposes should be carefully attached to lifting
tackle and secured. Use only suitable and technically perfect lifting gear and
suspension systems with adequate lifting capacity. Never work or stand
under suspended loads.
Loads should be fastened and crane operators instructed by experienced

persons only. The foreman giving the instructions must be within sight or
sound of the operator.
For carrying out overhead assembly work always use specially designed or
otherwise safety-oriented ladders and working platforms. Never use


ThyssenKruppRobins
machine parts as a climbing aid. Wear a safety harness when carrying out
maintenance work at heights.
Danger!
Do not carry out maintenance and repair work unless the machine/plant is
shut down.
Replace worn components without delay. Worn components are less stable
and are liable to break more easily.
Do not re-use seals and safety elements that have been removed.
Always use new bolts, nuts and washers when putting assembly groups and
parts back in place.
Do not leave tools or other devices on/in the machine/plant.
Observe the rules and regulations for the prevention of accidents when
welding work is carried out.
During electric welding, secure the earthing cable near the part being
welded. Do not route the welding current return line over movable machine
elements (e.g. shafts, bearings). For bridging fit a cable with across section
adequate for the welding current and for the distance to be covered by the
current.
Restore the machine/plant to its original state when repair work is

completed. Put protective and safety devices back in place. Make sure that
the machine/plant is working properly by carrying out a trial run.
4.4 Repair
Repair work is intended to restore the required condition of the

machine/plant by replacing defective components.


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4.5 Spare part stocks
Continuous operation and operational readiness of the machine/plant can

only be ensured when important spare and wear parts are kept in stock.
Please order spare parts using the information contained in the spare parts
list.
Our guarantee only refers to the original spare parts delivered by us.
Note!
We expressly point out that we do not assume any liability for spare parts
and accessories which have not been delivered by us. Foreign products
may have a negative effect on the characteristic features of the
machine/plant and impair safety. Damage caused by using products other
than the original spare parts and accessories are excluded from the
warranty.
Please note that parts manufactured by us and sub-suppliers are often

subject to special production and delivery specifications. But you may rest
assured that we shall always offer you state-of-the-art spare parts which
correspond to the latest legal regulations.


ThyssenKruppRobins
SPARE PARTS & SERVICE
Spare parts and service for the Conveying System is provided out of the
ThyssenKrupp Robins, Inc. office in Greenwood Village, Colorado.
TO ORDER SPARE PARTS CONTACT:
Michelle Miller
Phone: 303-770-0808 x. 624
Fax: 303-770-2153
or
-
Heather Hughes
Phone: 303-770-0808 x. 659
Fax: 303-770-2153
Spare Parts & Service

ThyssenKrupp Robins, Inc.
6400 S. Fiddler’s Green Circle, Suite 700
Greenwood Village, CO 80111
-
FOR SERVICE CONTACT:
Jürgen Lukas
Spare Parts & Service

ThyssenKrupp Robins, Inc.
Greenwood Village, CO 80111
Phone: 303-770-0808 x. 635

Fax: 303-770-2153
ThyssenKrupp Robins Inc.

Greenwood Village, Colorado
80111-5820, USA
Phone: 303-770-0808 Fax: 303-770-8233

610MR002-D
LUBRICATION SCHEDULE
PO Number: 25580-220-POA-MHCB-00001
Date: 21-Nov-2011
Equipment Lubrication
Qty. Supplier Equipment Description Mfg. Brand Lubrication Method Quantity Each Unit Frequency of Lubrication Initial Fill
Supplied Type / Spec / Mfg.
SACRIFICIAL CONVEYOR 0220-CVB-0001

PZOD2119 1 Sumitomo 250 KW Reducer Paramax Splash/ ISO VG220 or AGMA 5EP 180L. 1st Time after 500 h or six month, Unit is shipped
Machinery Corp. PDH9100R3- Forced Lubrication + approx. 20L. 2nd Time after 2500 h or six month, without lubricant
of America RLF-20 (lube system) Every 5000 h or one year
PZOD2119 1 Sumitomo Thruster Brake for 250KW Reducer Johnson Brake Manual Fill Invarol EP22 / ESSO 4.2 L. ones a year filled (100%)
Machinery Corp. CL10-EJ80/6
of America
PZOD2119 1 Sumitomo Thruster Brake Pivot Pins Johnson Brake Grease Teflon Grease / Dupont 0.1 L. Every 6 months filled (100%)
Machinery Corp. CL10-EJ80/6
of America
CZAO-5013 1 Siemens 250 KW Motor Siemens Grease Polyurea-base grease On Drive end: 31.2g, Every 3000 h or 6 months * 368.5 g
Industry On Non-drive end: 17g
(Capacity both: 368.5 g)
33593-A-ASM 1 RAS Head Pulley Ø 914x2130 FAG Grease Alvania / EP1 / Shell 86.4 g (1) Weekly 13 kg (100%)
33593-C-ASM 1 RAS Tail Pulley Ø 762x2130 FAG Grease Alvania / EP1 / Shell 46.4 g (1) Weekly 4.8 kg (100%)
33593-C-ASM 3 RAS Bend/ Take-UP Pulley Ø 762x2130 FAG Grease Alvania / EP1 / Shell 46.4 g (1) Weekly 4.8 kg (100%)
OVERLAND CONVEYOR 0220-CVB-0002

33593-D-ASM 1 RAS Head Pulley Ø 1830x1670 FAG Grease Alvania / EP1 / Shell 491.36 g (1) Weekly 47 kg (100%)
33593-D-ASM 1 RAS Bend Pulley Ø 1830x1670 FAG Grease Alvania / EP1 / Shell 491.36 g (1) Weekly 47 kg (100%)
34528-A-ASM 2 RAS Drive Pulley Ø 1830x1670 FAG Grease Alvania / EP1 / Shell 550 g (1) Weekly 80 kg (100%)
33593-E-ASM 1 RAS Bend Pulley Ø 1220x1670 FAG Grease Alvania / EP1 / Shell 89.04 g (1) Weekly 11.25 kg (100%)
33593-F-ASM 8 RAS FAG Grease Alvania / EP1 / Shell 46.4 g (1) Weekly 4.8 kg (100%)
Turn-Over Bend Pulley Ø 1000x167
33593-E-ASM 1 RAS Bend Pulley Ø 1220x1670 FAG Grease Alvania / EP1 / Shell 89.04 g (1) Weekly 11.25 kg (100%)
33593-G-ASM 1 RAS Tail Pulley Ø 1220x1670 FAG Grease Alvania / EP1 / Shell 89.04 g (1) Weekly 11.25 kg (100%)
33593-E-ASM 1 RAS Take-UP Pulley Ø 1220x1670 FAG Grease Alvania / EP1 / Shell 89.04 g (1) Weekly 11.25 kg (100%)
33593-E-ASM 8 RAS Turn-Over Supporting FAG Grease Alvania / EP1 / Shell 89.04 g (1) Weekly 11.25 kg (100%)
Pulleys Ø 610x1670
25K12004334 1 Joy Global Inc. Reducer, Active Take-UP Winch, Continental Oil bath lubrication JOY SEP320J OIL - P/N 100362728 40 L AS NEEDED filled (100%)
Continental Dwg. No. UD-26784 Crushing & Conv.
RR000902 1 Joy Global Inc. Motor, Active Take-UP Winch, Continental Grease Exxon Polyrex EM or Equal 28 g 18 Months filled (100%)
Continental Dwg No. UD-26784 Crushing & Conv.
610MR002-D
LUBRICATION SCHEDULE
PO Number: 25580-220-POA-MHCB-00001
Date: 21-Nov-2011
Equipment Lubrication
Qty. Supplier Equipment Description Mfg. Brand Lubrication Method Quantity Each Unit Frequency of Lubrication Initial Fill
Supplied Type / Spec / Mfg.
25KB106502375 1 Joy Global Inc. Brake, Active Take-UP Winch, Continental Oil bath lubrication Mobil ATF Type F Automatic Transmiss 6.63 L 6 Months filled (100%)
Continental Dwg No. UD-26784 Crushing & Conv.
4HPF25M-S23 1 American Winch, Head Pulley Winch Gear Thern Splash Lubrication Mobilgear 630/Mobil Oil Co., Chevron Gear Reducer Unit Oil levels and oil quality should be checked at filled (100%) with
Equipment, Inc. Removal; Reducer Non-Leaded Gear Compound KF 157: 31 L. frequent intervals, depending on usage. It is Mobilgear
220/CHEVRON Oil Co., Shell Omala Compound Drive Gear Unit not recommended to mix lubricants of different 630/Mobil Oil
Oil 220/Shell Oil Co., Meropa R 97: 5.1 L. brands. Oil changes required every 10,000 h Co.
220/Texaco Oil Co., BP Energol GP- or every 2 years.
XP 220/BP Oil Co., Kluberoil GEM 1-
Flange Thern Grease through the NLGI No.2 EP Grease Lubricant Pour at least every 10 h. of operation filled (100%)
Bearing Grease Zerk
23436994 1 American Maintenance Hoist, Gear Case YALE LIFT-TECH Manual Fill from vent hole on Chevron Universal Gear Lube 26.5 L. should be checked at frequent intervals filled (100%)
Equipment, Inc. Head Pulley Removal top of gear case. 85W-140, Mobilube HD 80W-90 depending on usage, as a minimum once a
Drain Point, Socket head month and lubricated as required. change
plug in bottom of gear case frequency is once a year.
Motor Brake YALE LIFT-TECH Manual Fill at Pivot Linkage Light Machine Oil Solenoid Actuated Apply should be checked at frequent intervals Lubricated
Linkage DTE Oil Heavy Medium one or two drops on linkage depending on usage, as a minimum once a
month to quarterly and lubricated as required.
Wire Rope YALE LIFT-TECH Manual Fill at Wire Rope Chevron 100 CB, or other prepared Light coat of lubricant should be checked at frequent intervals Lubricated
cable lubricant, Mobiltac 325 NC depending on usage, as a minimum once a
month to quarterly and lubricated as required.
Trolley YALE LIFT-TECH Manual Fill at Alemite Fittings Chevron Grease EP No.2, Pour Lubricant and should be checked at frequent intervals Lubricated
Mobilith AW 2 fill several pumps depending on usage, as a minimum once a
of a grease gun month to quarterly and lubricated as required.
BSFK 500-MS- 2 Svendborg Tail End Stopping Brake System Svendborg Manual Fill Mineral Oil: Tellus TX32/Shell, DTE 25L. Every 4000 h or 2 years None
200 Brakes Brakes (for filling instructions see 13M/Mobil, Rando HDZ32/Hydro
W/ DISC Maintenance Manuel section Texaco, Ultramax HVLP32/Valvoline;
Ø1500X60 4.6.4 & 4.6.5) Syntethic Oil: SHC 524/Mobil;
BSFK 500-MS- 2 Svendborg Head End Holding Brake System Svendborg Manual Fill Mineral Oil: Tellus TX32/Shell, DTE 25L. Every 4000 h or 2 years None
200 Brakes Brakes (for filling instructions see 13M/Mobil, Rando HDZ32/Hydro
W/ DISC Maintenance Manuel section Texaco, Ultramax HVLP32/Valvoline;
Ø2100X60 4.6.4 & 4.6.5) Syntethic Oil: SHC 524/Mobil;
CHHJS- 1 Sumitomo Drive Speed Reducer for Motorized Belt SM-CYCLO Grease Shell Alvania Grease 2 Seed Reduction Mechanism Replenishment: Every 500h - 1000h filled (100%)
6225DAY-377 Technologies Reel (NLGI Grade #2) (1st.Stage) 450g, (2st.Stage) Change: Seep Reducer Mechanism, High
2500g, Slow Speed Shaft Seep Shaft Bearings Every 2 -3 Y
Bearing (2nd Stage) 900g Slow Seep Shaft Bearings Every 3-5 Y
CHHJS- 1 Sumitomo Drive Chain for Motorized Belt Reel U.S. TSUBAKI Grease Ambient Temperature Range: 14°F- Oil is applied with an oil filler It should be applied about every eight Lubricated
6225DAY-377 Technologies 32°F SAE 30, Ambient Temperature or brush in the gap between hours of operation or as often as necessary to
Range: 32°F-104°F SAE 40 the pin link and roller link on prevent the bearing
the slack side of the chain. area of the chain from becoming dry
* Notes: -If motor is stored, rotate shaft several times a month by hand to recoat bearing surfaces.
- For severe duty (high ambien temperature, contamination or vibration), more frequent lubrication may be necessary.
Table of Contents
4 EQUIPMENT MANUALS
4.1 METAL DETECTOR MODEL 9000 ADVANCED DETECTION SYSTEMS
4.1.1 DATA SHEET METAL DETECTOR 190

4.1.2 INSTALLATION 195
4.1.3 TROUBLESHOOTING 206
4.1.4 REPLACEMENT OF ELECTRONIC CIRCUIT BOARD 210
4.1.5 CIRCUIT BOARD LAYOUT / ELECTRICAL SCHEMATIC 211
4.1.6 OUTLINE DRAWING — MODEL 9000 213
4.2 HOOD COVERS CAPOTEX
4.2.1 DATA SHEET HOOD COVER CONVEYOR 0220-CVB-0001 216

4.2.3 OPERATION & MAINTENANCE MANUAL 220
4.2.4 INSTALLATION DRAWINGS 221
4.3 IDLERS LORBRAND
4.3.1 DATA SHEET IDLERS CONVEYOR 0220-CVB-0001 227

4.3.3 OPERATING INSTRUCTIONS 255
4.4 BELT SCALE MERRICK INDUSTRIES, INC.
4.4.1 DATA SHEET BELT SCALE 272

4.4.2 CUSTOMER SUPPORT / SPARE PARTS 277
4.4.3 OPERATION AND MAINTENANCE INSTRUCTIONS 279
4.4.4 SPEED TRANSMITTER INSTALLATION AND PARTS MANUAL - DSP-825 312
4.4.5 CALIBRATION TEST CHAIN 318
4.4.6 BELT FEEDER CONTROL INSTALLATION, OPERATION AND MAINTENANCE MANUAL 333
4.4.7 PROGRAMMING DATA SHEETS 437
4.4.8 MOTORIZED WINCH 447
4.4.9 MECHANICAL DRAWINGS 465
4.4.10 ELECTRICAL DIAGRAM 471
Table of Contents
4.5 TAKE-UP WINCH P&H MINEPRO
4.5.1 DATA SHEET TAKE-UP WINCH 478

4.5.2 ASSEMBLYDRAWING UD-26784 481
4.5.3 OIL SHEAR MOTOR BRAKE 482
4.5.4 ENCODER INSTRUCTION MANUAL 522
4.5.5 MOTOR 534
4.5.6 VECTOR WINCH REDUCER 566
4.5.7 SYSTEM CONTROLS 595
4.6 CONVEYOR BELTS PHOENIX
4.6.1 OPERATING AND MAINTENANCE INSTRUCTION 626

4.6.2 CHECKLIST FOR SPLICING WORKS 642
4.6.3 BELT EP1600 644
4.6.4 BELT ST 5000 654
4.6.5 COMPARISON OF COVER GRADES 668
4.6.6 GUIDELINES FOR STORAGE AND HANDLING 669
4.7 BELT RIP DETECTION SYSTEM PHOENIX
4.7.1 GENERAL INSTALLATION INSTRUCTIONS 682

4.7.2 BELT LOOP MONITORING SYSTEM WITH RFID UNIT 689
4.7.3 BELT LOOP MONITORING SYSTEM VERSION 1.36 698
4.7.4 CONTROL CONCEPT STG-300-0233 707
4.8 CONVEYOR PULLEYS RAS
4.8.1 DATA SHEET PULLEYS CONVEYOR 0220-CVB-0001 743

4.8.2 DATA SHEET PULLEYS CONVEYOR 0220-CVB-0002 748
4.8.3 OPERATING & MAINTENANCE MANUAL PULLEY NO. 33593-A, -C, -D, -E, -F, -G 755
4.8.4 OPERATING & MAINTENANCE MANUAL GEARLESS MOTOR DRIVE PULLEY NO. 34528-A787
4.9 BELT CLEANERS RICHWOOD
4.9.1 DATA SHEET BELT CLEANER CONVEYOR 0220-CVB-0001 814

4.9.2 DATA SHEET BELT CLEANER CONVEYOR 0220-CVB-0002 817
Table of Contents
4.9.3 MODEL 1C INSTALLATION / SERVICE MANUAL 820

4.9.4 MODEL 1C-ITC INSTALLATION / SERVICE MANUAL 837
4.9.5 MODEL 1C, 1C-ITC, INSTALLATION REFERENCE DRAWING 855
4.9.6 MODEL VP-SA SWING ARM V-PLOW INSTALLATION / SERVICE MANUAL 856
4.10 DRIVE MOTOR SACRIFICIAL CONVEYOR SIEMENS
4.10.1 SAFETY PROCEDURES 865

4.10.2 INTRODUCTION 866
4.10.3 INSTALLATION 868
4.10.4 OPERATION 873
4.10.5 MAINTENANCE 876
4.10.6 SPARE PARTS 888
4.10.7 MOTOR SERVICE RECORD 892
4.10.8 VIBRATION ANALYSIS SHEET 893
4.11 GEARLESS MOTOR SIEMENS
4.11.1 OPERATING / INSTALLATION INSTRUCTIONS 898

4.11.2 TECHNICAL DATA AND DRAWINGS 1003
4.11.3 ACCESSORY EQUIPMENT 1026
4.12 REDUCER, PARAMAX 9000 SUMITOMO
4.12.1 DATA SHEET GEAR REDUCER 1167

4.12.2 DRAWING PZOD2119 1170
4.12.3 REDUCER MAINTENANCE MANUAL 1171
4.12.4 GEAR COUPLINGS 1229
4.12.5 THRUSTER BRAKE 1246
4.12.6 OIL PUMP 1259
4.12.7 FLOW MONITORING 1331
4.12.8 IMMERSION HEATERS 1349
4.12.9 TEMPERATURE SWITCH DATA SHEET 1362
4.12.10 OIL LEVEL SWITCH 1363
4.12.11 VIBRATION SENSOR 1368
4.13 MOTORIZED BELT REEL SUMITOMO
4.13.1 DATA SHEET BELT REEL REDUCER 1373

4.13.2 GEARMOTOR & REDUCER O & M MANUAL 1375
4.13.3 CYCLO 6000 INSTALLATION AND QUICK-START GUIDE 1434
4.13.4 LONG TERM STORAGE PROCEDURE 1452
4.13.5 GEARMOTOR LUBRICATION SCHEDULE 1454
4.13.6 REDUCER TECHNICAL INFORMATION 1460
4.14 CONVEYOR BRAKES SVENDBORG
4.14.1 DATA SHEET TAIL END STOPPING BRAKE 1466

4.14.2 DATA SHEET HEAD END HOLDING BRAKE 1468
4.14.3 INSTALLATION & MAINTENANCE HYDRAULIC DISC BRAKE BSFK 500 1470
4.14.3 INSTALLATION & MAINTENANCE BRAKE CONTROL UNIT TAIL END STOPPING BRAKE 1518
4.14.3 INSTALLATION & MAINTENANCE BRAKE CONTROL UNIT HEAD END HOLDING BRAKE 1550
4.14.4 HYDRAULIC SETTINGS 1582
4.14.5 USERS MANUAL SOBO CONTROLLER 1583
4.14.6 USERS MANUAL SOBO PROFIBUS INTERFACE 1629
4.14.7 USERS MANUAL PU PROFIBUS INTERFACE 1637
4.14.8 SENSIE BRAKE INDICATOR 1643
4.15 WINCH HEAD PULLEY REMOVAL THERN
4.15.1 DATA SHEET WINCH 1650

4.15.2 OWNER’S MANUAL 1652
4.15.3 MOTORS AND BRAKEMOTORS OPERATING INSTRUCTIONS 1675
4.15.4 GEARMOTORS AND GEAR REDUCERS OPERATING INSTRUCTIONS 1681
4.16 HOIST HEAD PULLEY REMOVAL YALE
4.16.1 DATA SHEET HOIST 1688

4.16.2 PARTS AND INSTRUCTION MANUAL 1692
Table of Contents 4 Eqpt. Manuals
4.1 METAL DETECTOR
ADVANCED DETECTION SYSTEMS, METAL DETECTOR MODEL 9000A
4.1.1 DATA SHEET METAL DETECTOR 190
4.1.2 INSTALLATION
4.1.2.1 MECHANICAL 195
4.1.2.2 ELECTRICAL 198
4.1.2.3 TERMINAL CONNECTIONS CHART 200
4.1.2.4 START-UP PROCEDURE 203
4.1.2.5 SENSITIVITY DIP SWITCH SETUP 205
4.1.3 TROUBLESHOOTING 206
4.1.4 REPLACEMENT OF ELECTRONIC CIRCUIT BOARD 210
4.1.5 CIRCUIT BOARD LAYOUT / ELECTRICAL SCHEMATIC 211
4.1.6 OUTLINE DRAWING — MODEL 9000 213

Table of Contents 4.1 Metal Detector 4 Eqpt. Manuals
Metal Detector Data Sheet_RA Completed Revised
Antapaccay Project ThyssenKrupp Robins

Job No.: 1002 Eng. Approval September 23, 2010
RFQ Number: 1002-007 Checked By: Rev A
Vendor Data: Units Krupp Spec. VENDOR

Advanced Detection Systems
Company Name
4740 W Electric Ave. Milwaukee,
Company Address
WI 53219
Contact Person Nikki Campbell
Telephone Number 414-672-0553
Fax Number 414-672-5354
e-mail Address ncox@adsdetection.com
Proposal Reference Number 7001
Date of Proposal October 6, 2010
Technical Specifications:
Belt Conveyor Number: CVB-0001
Equipment Tag Number
Material Copper Ore
Lump Size mm 305
Belt Width mm (in) 1830 (72)
Trough Angle degrees 35
Capacity mtph 5263
Density (for volume / for mass) kg/m3 1600 / 1890
Belt Speed m/s 2.9
Surcharge degrees 25
Bed Depth mm 341
Cross Sectional Area m^2 0.315
Site Elevation m (above sea level) 4200
Ambient Temperature (°C) Minimum -10
Ambient Temperature (°C) Maximum 23
Model
Model Number 9000 SurroundScan
Type Solid State Yes
Principle of operation Eddy Current Principle Yes
Shape of Metal Bolt 1"x6" Yes

Size of Metal mm 37 mm sphere
Detection of Non-Ferrous Particle Possible? yes Yes
Size of Non-Ferrous mm 42 mm Sphere
Detection of Non-Magnetic Particle Possible? yes Yes
Size of Non-Magentic mm 62 mm sphere
Maximum Burden Depth considered mm 24"
Materials of Construction Frame 3/16" steel
Materials of Construction Coil Copper wire and GPO
Marking System:
Paint Yes Yes
Controls:
Type of Actuation Provided Contact closure
Actuation On detect of metal
Provision of Electrical Isolation of Idlers? No No required
Provision of Alarm Indication? Yes Yes
Audible Distance of Alarm m 100
Alarm Horn Yes / No Yes No
Flashing Beacon Yes / No Yes Yes
Manual Reset Yes / No Yes Yes
Clip Detector for Mechanical Splicing Yes / No Yes Yes
Provision for Suppressing False Alarm? Yes / No Yes Yes
Details of control panel with degree of protection of Yes / No Yes Yes
enclosure
Mounting:
1 of 2
12/5/2011

Job No.: 1002 Eng. Approval September 23, 2010
RFQ Number: 1002-007 Checked By: Rev A

Advanced Detection Systems
Company Name
Mounting Arrangement To Be Provided Bolt to frame
Mounting Hardware Provided Yes / No yes No
Power:
Power Supply to Metal Detector Volts / Phase / Hz 120/1/60
Degree of Protection of enclosure for junction box NEMA 4 Enclosure NEMA 4
mounted on conveyor structure/equipment
Provision of Controls and Interlocks? Yes / No Yes No

Special Requirements, if any No
Paint:
Paint - Frame & Coils Water based enamel
Primer Specification Yes
Primer Thickness mils
Finish Coat Specification
Finish Coat Thickness mils
Finish Color Blue
Weights:
Overall Approximate Dimensions L x W x H, Inches 72" x 19" x 48" high
Weight of Total Assembly kg 1430
Shipping Dimensions mm LxWxH 1980 x 610 x 1520
No. of Metal Detectors Offered 1 1
Technically Acceptable Yes/No Yes
2 of 2
12/5/2011
MODEL
9000
METAL
DETECTOR
with Series 9000A circuit board
Installation
and Operation
Manual
Table of Contents
Installation ..................................................................................................1
Notes ..............................................................................................................2
Electrical Installation...................................................................................3
Terminal Connections Chart ......................................................................4
Metal Marker ...............................................................................................5
Splice Detector..............................................................................................5
Start-up Procedure ......................................................................................6
Sensitivity DIP Switch Setup ......................................................................8
Troubleshooting Guide - Basic ...................................................................9
Troubleshooting Guide – Advanced...........................................................10
Replacement of Electronic Circuit Card ...................................................12
Circuit Board Layout ..................................................................................13
Electrical Schematic.....................................................................................14
Outline Drawing — Model 9000 .................................................................15

MECHANICAL INSTALLATION
Conveyor belt not yet in place:
The metal detector should be mounted midway between idlers and away from any motors, pulleys, or
magnets.
Lower the unit carefully into position over the predrilled stringers. Bolt the metal detector securely into
position and ensure that when the belt is installed that there is 2” clearance between the underside of the
conveyor belt and the bottom of the metal detector.
Conveyor belt already in place:
The metal detector should be mounted midway between idlers and away from any motors, pulleys, or
magnets.
The end OPPOSITE the control cabinet is detached by removing the 16 hex head bolts – eight on top
and eight on bottom.
The belt is then raised and the metal detector is slid into position around the conveyor belt. A suitable
support such as wooden planks should be used to support the detector during this phase of the
installation. NOTE: Care should be taken in lifting the metal detector. Under no circumstances should
be unit be lifted by the open end of the top sensing head.
The end plate should now be replaced and the bolts tightened to 70 foot-pounds.
The unit should be raised slightly to allow the supports to be removed.
The metal detector is then lowered between the stringers until the mounting feet rest on top of the
stringers.
The mounting holes of the unit are then aligned with the predrilled holes in the stringers and the two
units are securely bolted together.
Extra holes must not be drilled into the body of the metal detector.
The body of the metal detector must not be twisted or strained in any way.
There should be a 2” clearance between the underside of the belt and the bottom sensing head of the
metal detector.
The detector is now ready for wiring to a power source and any auxiliary devices.
Page 1
Install sensor 3” upstream of idler.
Typical Splice Sensor, Metal Detector and

Metal Marker Installation
NOTES:
1. If the conveyor belt has a metal belt splice or metal repair clips, then the metal detector will
require the use of an optional belt splice sensing system for correct operation.
2. When the metal detector is fitted with a remote mounted control cabinet, the cabinet should be
securely mounted to a solid structure. The cable from the sensing head to the control cabinet
should be run in conduit and be securely fastened every 12”.
3. Belts, slides, guides, etc. must not rest on the lower sensing head or touch the sides of the metal
detector aperture.
4. Pipes, conduits, etc. must not pass through the aperture of the metal detector.
5. Under no circumstances should the end plate fitted with the control cabinet be removed.
6. All metal detectors require a “metal free zone”. The metal free zone for the Model 9000 detector
is 48”. The detector should be mounted in the center of the 48” metal free zone. If the idler
spacing is less than 48”, the rollers of the idler could interfere with the detector and should be
replaced with high impact rubber. The metal free zone is shown in the Model 9000 outline
drawing shown below and on page 15 of this manual.
Page 2
Electrical Installation
The metal detector is designed to operate on 115 vac +/- 10% and requires 40 watts of power.
Units are available to operate on 230 vac.
A power feed free of motor start-up transients or other interference should be used.
All electrical connections to the metal detector are made to a terminal panel inside the control
cabinet.
A terminal connection chart is shown on page 4 of this manual.
All relay contacts are rated at 240 volts, 1000 va maximum.
Terminals 4, 5 and 6 are a set of isolated contacts that change over and latch when metal is detected.
All relays contacts are reset by momentary contact closure of terminals A & B on the right hand side
of the terminal strip or by depressing the reset button mounted on the control cabinet door.
Terminals 7, 8 and 9 provide a source of 115 vac for the operation of the “Ready” and “Detection”
lights and the metal marker system (if supplied). Please refer to the electrical wiring diagram and
also the electrical connection chart on page 6 for details.
On detection of metal, the red detection light on top of the control cabinet turns on. This light is
turned off by the metal detector reset button.
Power to the metal detector should be left on at all times, whenever possible.
Page 3
Model 9000A
Terminal Connection Chart
Terminal Function
1 Power input. Hot line.
2 Power input. Neutral line.
3 Ground line input.
4 Isolated contact set. Normally closed contact.
5 Isolated contact set. Common contact.
6 Isolated contact set. Normally open contact.
7 On detection of metal, a briefly connected hot line out.
8 On detection of metal, a briefly interrupted hot line out.
9 On detection of metal, a constant hot line out.
12, 15, 16 Constant neutral line out.
A&B Metal detector reset. Wired to normally open contact of metal

detector reset switch.
C&D Splice detector input. Wired to optional belt splice sensing system.
Page 4
Typical Splice Sensor, Metal Detector and

Metal Marker Installation
Metal Marker
On detection of metal, the optional metal marker assembly will drop a brightly colored disc of plastic
material onto the conveyor belt at the approximate location of the metal contamination.
The metal marker should be located outside the metal detector’s metal free zone to avoid false triggers
caused by the movement of the mechanism. The recommended distance is 36” from the metal detector.
The timing of the metal marker can be controlled by the “delay” adjustment in the metal detector control
cabinet. Adjust the delay time until the colored block falls directly on top of the belt where the
contamination is located.
The metal marker is wired to the metal detector via terminal 7 (normally open contact) and a neutral
terminal (2, 12, 15, or 16).
The metal marker will not operate during the one minute warm up time of the detector.
Belt Splice Sensing System

The optional belt splice sensing system is required if the conveyor belt has a metal splice or metal repair
clips.
The splice detector sensing head is mounted approximately 24” upstream from the metal detector. It
should be mounted near the edge of the conveyor belt and parallel to the belt. Please refer to the sketch
on the opposite page. The sensor should be mounted 3” upstream from the idler.
In some instances, the belt splice sensor may not be able to detect the splice as it approaches the
detector. This may be because the splice is relatively small or it may be made of a type of metal that is
hard to detect, such as stainless steel. It may be necessary to install a “target” on the splice to ensure
detection. A typical “target” would be a 4” square piece of steel shim stock installed on the conveyor
belt with bolts or pop rivets.
The theory of operation of the belt splice sensing system is quite simple. As the splice approaches the
metal detector, it is first detected by the splice sensor. The splice sensor sends a signal to the metal
detector and tells it to reduce its sensitivity to allow the belt splice to pass undetected. The sensitivity of
the metal detector during this time is controlled by the “Splice Sensitivity” and the amount of time is
controlled by the “Splice Time”. The “Splice Time” should be set long enough to allow the splice to
pass totally through the metal detector zone. If the detector comes back to full sensitivity too soon, it
will detect the splice as it leaves the metal detector zone.
The “Splice Sensitivity” can be set from 0-10. At 10, the detector has 100% of normal sensitivity. At 5,
it has 50% of normal sensitivity and at 0, the detector is virtually turned off. The idea is to reduce the
sensitivity of the metal detector to the point where it will just allow the splice to pass undetected.
The unit is supplied already wired. Please refer to the electrical schematic on Page 14 for details.
Page 5
Start-Up Procedure
Metal detector installed without belt splice sensing system:
Turn Power on to the metal detector.
Allow approximately one minute for the metal detector to warm up and calibrate itself.
Press the reset button on front of the metal detector.
Place a jumper across the two pins labeled “L” and “D” on the circuit board of the metal detector. The
pins are located just above terminals 15 & 16. This will prevent the metal detector from stopping the
conveyor during the set-up process.
With the conveyor belt loaded with a typical burden of product, set the “Sensitivity” control to 4 and
begin with the “Product” control set to 1. Allow the product to run and determine if the metal detector is
triggering on the burden. If the metal detector fails to reset, or if it trips constantly, move the “Product”
control to 2. Keep the “Sensitivity” control at 4. Please note that the detector may trip when you move
the settings from one number to another. This is normal for both the “Product” and “Sensitivity”
controls. Move the setting and then give the detector a moment to settle down before changing the
setting again. Continue increasing the “Product” control one number at a time until the metal detector
resets and does not trip on the product. Make note of the setting on the “Product” control where it
allows the product to pass. Continue to increase the setting one number at a time until the metal detector
again begins to trigger on the burden. Make note of this setting also. Set the “Product” control midway
between the two settings you just determined. Now increase the “Sensitivity” control one number at a
time until the detector begins to trip on the product (or burden). When it does, reduce the sensitivity one
or two numbers and that should be the final setting. These settings should hold true unless there is a
large change in the moisture level of the product or the mass of the burden.
Remove the jumper from the “L” & “D” pins and test the metal detector by dropping a piece of metal on
the conveyor belt before the metal detector. The red light on the top of the detector should come on and
the conveyor should stop.
Metal detector installed with belt splice sensing system:
Turn Power on to the metal detector.
Allow approximately one minute for the metal detector to warm up and calibrate itself.
Press the reset button on front of the metal detector.
Place a jumper across the two pins labeled “L” and “D” on the circuit board of the metal detector. The
pins are located just above terminals 15 & 16. This will prevent the metal detector from stopping the
conveyor during the set-up process.
Stop the conveyor belt.
Page 6
Set the front panel controls to the following settings:
Product 1
Sensitivity 0
Splice Sensitivity 0
Splice Time 2
Operate 2
Delay 2
Run the conveyor belt without product and make sure that the belt splice sensor is detecting the metal
splice each time it passes the sensor. This can be determined by watching the red light, labeled “Splice
Sensitivity”, in the lower right hand corner of the detector circuit board. It should go out for
approximately two seconds each time the metal splice passes the sensor. If this does not happen, stop
the conveyor belt and loosen the two “U” bolts holding the sensor and move it closer to the belt. It is
important that the belt splice sensor “see” the splice every time.
Set the front panel controls to the following settings:
Sensitivity 10
Splice Sensitivity 0
Splice Time 10
Run the conveyor and increase the “Splice Sensitivity” one number at a time until the splice is detected
by the metal detector. On detection, the green “Ready” light on top of the metal detector will flash
briefly. Set the “Splice Sensitivity” one number below the point at which the splice is detected.
Run the conveyor and reduce the “Splice Time” one number at a time until the splice is again detected
by the metal detector. Leave the “Splice Time” set just above the point where the splice is detected by
the metal detector.
Test the functioning of the metal detector by passing a suitable test piece of metal through the detector.
The green “Ready” light should go out briefly with each detection.
Adjust the sensitivity of the metal detector as required.
Remove the jumper from the “L” & “D” pins.
Set the detector up for product as described in the previous section.
Page 7
Sensitivity DIP Switches

The sensitivity DIP switches are located just below the control panel in the center of the circuit. They
can be viewed as a coarse sensitivity adjustment. The DIP switches are set at the factory and would not
normally need to be adjusted in the field. If the metal detector is to be used in an unusually harsh
environment or in a location of excess vibration, the DIP switches may need to be altered.
The DIP switches are made of four slide switches mounted in a block on the circuit board. Each slide
switch has a value. The lowest sensitivity is achieved when the DIP switches are all to the left. The
value of each switch is as follows:
Yellow 10
Orange 1.5
Red 0.1
Brown 0.0
When each switch is moved to the right, the sensitivity is increased by the switch value.
All metal detectors are shipped from the factory with the Orange switch to the right for a value of 1.5.
This is the normal setting of the DIP switches. The detector can be made slightly more sensitive by also
moving the Red switch to the right. Only in extremely good environments can the Yellow switch be
moved to the right. At increased sensitivity not only is the detector more sensitive to metal particles, it
also becomes more sensitive to outside interference such as vibration or electrical noise.
Timer Control DIP Switch

Once metal has been detected and the output relays have been activated, it is up to the timer control DIP
switch to determine how the relays will reset to be ready for the next trigger. The Timer control DIP
switch is located near the center right hand side of the main circuit board. (See layout drawing in this
manual). In the Latch or Up position the relay will stay in the detected state until the reset button on the
front of the metal detector door is pushed. A remote reset button may also be used to reset the detector.
When the timer control DIP switch is set to the toggle or down position, the Delay and the Operate
controls determine the action of the output relay. The Delay control determines the amount of time
delay between when the detector “sees” metal and when the output relay activates. This is useful when
some type of a reject device or marking device is used. The Operate control determines how long the
relay is activated. Again, this is useful with reject devices and markers.
Page 8
MODEL 9000A
TROUBLESHOOTING GUIDE
BASIC
The metal detector has on its control card a number of red indicators or LED’s which monitor the
performance of the metal detector and indicate coil or circuit failures. There are three LED’s on the
front panel in a horizontal line called the Diagnostic LED’s. There is also a status LED above each of
the detector’s blue output relays located on the lower center of the circuit board.
Normal Operation:
The Diagnostic LED’s should be lit as follows: the left LED should be on, the center LED may be on
dim or it may be off, the right LED should be off.
The two lower LED’s above the two relays should be on. Each of these LED’s indicate the status of the
relay below it. The right hand relay is called the “Pulse” relay and the left hand relay is called the
“Latch” relay.
Detection of Metal:
On detection of metal, the three Diagnostic LED’s remain unchanged. A very large piece of metal will
cause the LED’s to brighten considerably.
The lower right hand Pulse LED will go out briefly and then come back on. The lower left hand Latch
LED will go out and stay out until the reset button on the front door of the metal detector cabinet is
pressed.
Page 9
ADVANCED
As a minimum, a volt/ohm meter is required for the advanced troubleshooting section. It would be quite
helpful to have an oscilloscope for some of the tests mentioned.
A brief description of the theory of operation of the detector will help make the following tests more
understandable.
The metal detector is basically a transmitter and a receiving antenna. The transmitting coil is located in
the upper section of the inspection head and the two receiver coils are located in the bottom. The
transmitter generates an RF field that induces a constant voltage into the receiver coils. One receiver
coils is wired positive and the other is wired negative. Because they have the same voltage in each coil,
when they are added together, the final output of the two coils is zero. This is known as a “balanced
field” detector and maintains very good sensitivity as long as the two coils remain equal, or balanced.
As a piece of metal passes through the field, it will upset the balance of the coils. This is seen by the
electronics of the detector which then triggers output circuits to shut down the conveyor belt or sound
alarms of some kind. Some products are conductive in nature and will disturb the field balance also.
There is a “product” control on the front panel that is used to minimize the effects of conductive
materials.
Please refer to the circuit board layout and operating controls on the opposite page during the
following discussion.
Very basic items should be checked to make sure that the circuit board is at least working. The detector
uses + and – 12 volts DC. The + 12 can be measured at the + 12 test point near the left center of the
circuit board. Likewise, the -12 can be measured at the -12 test point. These are both measured with
respect to ground (Gnd). The metal detector should be turned off and the coils of the detector should
also be checked for continuity. The transmit coil plugs onto the left, top of the circuit board at the
connector marked “OSC”. If you remove the cover of the plug, you will see a clear wire, a blue wire,
and the ground shield. If you measure between the blue and clear wires, you should measure some low
resistance reading, around 3 ohms. It will vary slightly from detector to detector. If it is open or
shorted, the transmitter coil is probably bad and should be replaced. Since the ohm meter reading is very
low, it is easy to assume that it is shorted. This should be checked carefully. Make sure that the
connections are good and there are no “cold solder joints” or shorts between connections. Also make
sure that there is no possibility that they could be shorted to the connector when the cover is put back on.
The receiver coils plug into the top, right of the circuit board at the connect marked “PU”. Remember
that there are two receiver coils. Although there are four pins in the receiver connector, only the first
three are used, the fourth is not connected. Again, there is a blue, clear, and shield wire from the
receiver coils. If you measure between the shield and the blue wire, the resistance should be somewhere
between 50 and 125 ohms. The actual value is not important as long as it is not shorted or open. If you
measure between the shield and the clear wire, you should get the same value. The blue wire is one coil
and the clear wire is the other coil and the shield is the ground for both. Again, make sure there are no
cold solder joints and that there are no shorts or broken wires.
Page 10
The following checks require the use of an oscilloscope.
The first item to be checked is to make sure there is a good signal at the transmitter coil. The is done at
TP6 on the upper left of the circuit board. This should be a clean sine wave of about 15 to 16 volts
peak-to-peak. The frequency is just over 4 Khz. If it is distorted, it can cause false triggers of the metal
detector. It is adjusted using the transmitter drive adjustment located just below the heat sink in the
upper left hand corner of the circuit board. The level is set by increasing the drive (clockwise) until the
signal starts to deform. Then back off enough so that the signal is clean and free from distortion.
The receiver signals can be seen at the upper right corner of the circuit board at TPA for one coil and
TPB for the other coil. These are generally small, in the range of 10 to 50 millivolts. They should be a
clean sine wave and should be of equal value. These signals are actually slightly different but the
difference cannot be seen with the oscilloscope. The signals are set against each other, or balanced, to
get the smallest possible signal at TP2. This is done at the factory and should not need to be adjusted in
the field. In order to get the signal at TP2 as low as possible, resistors and capacitors are added to TPA
and/or TPB to make the two signals as identical as possible. The closer they are to being equal, the
smaller the signal will be at TP2 and the dimmer the diagnostics lights will be because they follow the
signal at TP2. If the resistors or capacitors used for balancing are broken, then the unit will be out of
balance and the diagnostic LED’s will be brighter than normal. Observe the three diagnostic LED’s.
They function as a basic bar graph. Normally the left LED will be lit but dim, the center LED will be
out, and the right LED will be out. If, for some reason, the LED’s get brighter, or the right LED begins
to light, it is an indication that the detector is “out of balance” and steps need to be taken to correct the
situation, Call the factory. There is automatic circuitry on the circuit board to maintain the correct
balance of the detector after the initial balancing components have been selected. If you suspect the
unit is out of balance, check the LED’s. The first symptom of an out of balance condition is degrading
of sensitivity, followed by false triggers of the detector. There is automatic circuitry on the circuit
board to maintain the correct balance of the detector. If the signal at TP2 is small, less than 2 volts
peak-to-peak, then the metal detector is considered to be “in balance” and we can move on to additional
testing.
The last major test point is TP12B. This is a changing DC signal that shows the detection level of the
circuitry. The signal hovers around zero volts and changes with the product passing through the detector
coils. If this signal moves positive or negative more than 150 millivolts, the metal detector will trigger.
In general, if there is no product or metal passing through the detector, the level should not move beyond
+ or – 75 millivolts. This is a good spot to check when trying to determine what might be causing false
triggers of the detector. You can watch TP12B and walk around the detector shaking and moving things
to see if there is any reaction at the test point.
If all else fails, give us a call at the factory. We will be more than happy to assist in any way we can.
Page 11
Replacement of Model 9000A Electronic Circuit Board

To replace the circuit board:
1. Turn off the power to the metal detector. Be sure all additional sources of power to the
output circuits have also been turned off.
2. Disconnect the two large plugs near the top of the circuit board.
3. Unplug and remove the small rectangular “Balance Board” in the upper right hand corner
of the circuit board. This small board contains the components necessary to “tune” the
circuit board to the detector coils. These components are part of the coil circuit and must
remain with the detector. (On some earlier models the components are soldered directly
to the test pins TPA, TPB, and COMM. These must be unsoldered and moved to the new
circuit board)
4. Remove the wires from the terminals at the bottom of the circuit board. It’s a good idea
to tag each of the wires for easier relocation.
5. Remove the six screws that hold the circuit board in place.
6. Remove the circuit board and put it in a safe place. The replacement circuit board is
shipped in a conductive pouch. The defective circuit board should be placed into the
pouch and returned to the factory for repair.
Installation is the reverse of the above. Make sure to re-install the “Balance Board” on the new circuit
board.
NOTE: The new circuit board should be installed with its controls set to the same settings as the original
circuit board.
Page 12
Page 13
Page 14
Page 15
4740 W. Electric Avenue

Milwaukee, WI 53219
414/672-0553
414/672-5354 Fax
www.adsdetection.com
4.2 HOOD COVERS
CAPOTEX, HOOD COVERS
4.2.3 OPERATION & MAINTENANCE MANUAL 220
4.2.4 INSTALLATION DRAWINGS 221

Table of Contents 4.2 Hood Covers 4 Eqpt. Manuals
Hood Cover Data Sheet_RA CAPOTEX

Job No.: 1002 Eng. Approval August 13, 2010
RFQ Number: 1002-00X Checked By: Rev A

Company Name CAPOTEX 2000, S.L.
C/ COLOMBIA, 1. MAJADAHONDA. 28220
Company Address
MADRID. SPAIN
Contact Person MARTIN SCHMIDT
Telephone Number +34 916 347 192
Fax Number +34 916 362 115
e-mail Address m.schmidt@capotex.com; capotex@capotex.com
Date of Proposal 08/25/2010
Belt Conveyor Number: 0220-CVB-0001
Material Copper Ore
Density kg/m^3 1600
Capacity mtph 5,263
Trough Angle (Top / Bottom) Straight area sections degrees 35 /15
Trough Angle (Top / Bottom) Curved area sections degrees N/A
Belt Width 1830 (72) - Wide
mm (in)
Base
Carry Idler Spacing m 1.2
Return idler spacing m 3.6
Max. Lump Size mm 305
Belt Speed m/sec 2.9
Temperature °C -10 to 23 °C
Ref Drawing
Hood Covers:
Type Corrugated hinged cover
Corrugated hinged
cover
Model MADRID
Length, Straight Sections m 62 62
Length, Horizontal Curve Sections m 0 0
Length, Total m 62 62
Weight of Cover Section (each) kg 26
Hood Coverage (length per segment) m 1.292
Hood Coverage Full Full
Inside Radius mm 1175+ 1175
Tangents mm 152+ 152
Inspection Door Spacing m N/A
Inspection Door Size mm x mm N/A
Material Steel Galvanized Steel
Thickness of Cover gauge GA 24 (edges of GA 18)
Special Hardware Included C-1 Lock/Hinge. Steel angle. Self-drilling
Provide Description screws.
Hardware Materails of Construction Galvanized Steel and DACROMET 500
Hardware Quantity per Hood Unit 4
Hinge Mounted to Stringer Yes/No (see note 1) Yes yes
Number of Hood Units required each 48
Shipping Dimensions mm LxWxH 2550x1350x1800 (1 PALLET)
Shipping Weight kg 1520
Bands:
Support Type
Support band spacing (typ) m 1.2
Support band width mm
1 of 2
12/5/2011


Minimum overlap mm
Weight of Band (each) kg
Mounting Method Angle, Plate, etc.
Connection to Stringer Bolted
Lateral Bolt Hole Spacing mm 2210
Bolt Hole Spacing mm
Inside Radius mm 1175-
Tangents mm 152-
Material Steel
Thickness of Band gauge
Units Required each
Shipping Dimensions mm LxWxH
Shipping Weight kg
Technically Acceptable Yes/No
Notes:
1 - Please provide drawing of hinge details.
2 - Please advise any special mounting requirements for all components.
2 of 2
12/5/2011


C/ COLOMBIA, 1. MAJADAHONDA. 28220
Company Address
MADRID. SPAIN
Contact Person MARTIN SCHMIDT
Fax Number +34 916 362 115
e-mail Address m.schmidt@capotex.com; capotex@capotex.com
Date of Proposal 08/25/2010
Belt Conveyor Number: 0220-CVB-0002
Material Copper Ore
Density kg/m^3 1600
Capacity mtph 5,263
Trough Angle (Top / Bottom) Straight area sections degrees 35 /15
Trough Angle (Top / Bottom) Curved area sections degrees 35 /15
Belt Width 1372 (54) - Wide
mm (in)
Base
Carry Idler Spacing m 1.4
Return idler spacing m 4.2
Max. Lump Size mm 305
Belt Speed m/sec 6.2
Temperature °C -10 to 23 °C
Ref Drawing
Hood Covers:
Type Corrugated hinged cover
Corrugated hinged
cover
Model MADRID
Length, Straight Sections m 4450 4450
Length, Horizontal Curve Sections m 2070 2070
Length, Total m 6520 6520
Weight of Cover Section (each) kg 17
Hood Coverage (length per segment) m 1.292
Hood Coverage Full Full
Inside Radius mm 980+ 980
Tangents mm 250+ 250
Inspection Door Spacing m N/A
Inspection Door Size mm x mm N/A
Material Steel Galvanized Steel
Thickness of Cover gauge GA 24 (edges of GA 18)
Special Hardware Included Yes C-1 Lock/Hinge. Steel angle. Self-drilling
Provide Description screws.
Hardware Materails of Construction Galvanized Steel and DACROMET 500
Hardware Quantity per Hood Unit 4
Hinge Mounted to Stringer Yes/No (see note 1) Yes yes
Number of Hood Units required each 5047
Shipping Dimensions mm LxWxH 2200x1350x1700 (100 PALLETS)
Shipping Weight kg 105,000
Bands:
Support Type
Support band spacing (typ) m 1.4
Support band width mm
1 of 2
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Minimum overlap mm
Weight of Band (each) kg
Mounting Method Angle, Plate, etc.
Connection to Stringer Bolted
Lateral Bolt Hole Spacing mm 1752
Bolt Hole Spacing mm
Inside Radius mm 980-
Tangents mm 250-
Material Steel
Thickness of Band gauge
Units Required each
Shipping Dimensions mm LxWxH
Shipping Weight kg
Technically Acceptable Yes/No
Notes:
1 - Please provide drawing of hinge details.
2 - Please advise any special mounting requirements for all components.
2 of 2
12/5/2011
OPERATION & MAINTENANCE MANUAL
OPERATION:
x Use personal protection equipment according to local regulations.

Specially recommended are gloves to manipulation sharp objects, safety
boots and helmet.
x Handle the covers with care. They could have sharp edges.
x Pick up the covers with a minimum of two persons. One on each side.
x Do not handle covers under adverse weather conditions (strong wind,
electric storm).
x Handle the covers one by one.
x Do not leave covers without fastening to avoid the risk of falling down.
MAINTENANCE:
x Store original packed dry and beneath of roofage.

x Packages are not stackable.
x When covers are piled up in packages, galvanized steel sheets are
sensible to humidity, condensation and rain. Water infiltrated between
steel sheets could benefit the formation of a hydrocarbon of zinc,
common named ‘white oxide’
That kind of oxide is not dangerous for the lacade, but has an esthetical
impact.
It is recommendable to protect galvanized elements from rain and
storage as dry as possible.
1292mm ±30 1292mm ±30 1292mm ±30 1292mm ±30
50 7/8" ±1,181 50 7/8" ±1,181 50 7/8" ±1,181 50 7/8" ±1,181
CORRUGATION DETAIL
76mm
18mm
3"
3/4"
Stiffening seal
Sheet thickness 0.6mm [Gauge 24]

and 1.2mm [Gauge 18] in edges.
1867mm 1400mm 1400mm 1400mm
18mm
73 1/2" 55 1/8" 55 1/8" 55 1/8"
3/4"
4200mm
165 3/8"
4" m
3/ 5m
36 33,
9
R
B
A
A 250 mm - [ 9 7/8" ]
B 1183 mm - [ 46 5/8" ]
QTY 5975 m.
1822mm
71 3/4"
CS-3433
NOT SPECIFIED TOLERANCE

SCALE DESIGNED DRAWN CHECKED SHEET 1 OF 6 FORMAT
CAD DRAWING. HANDLING ON CAD SYSTEM ONLY AME EUR
DATE 04-05-11 . .
DIMENSIONS ANGLES 1:20 SIGNATURE P.GLEZ . J.SAURA A3
NAME REV.
() : ±2.00 0º : ±02' 00'' MADRID CLASSIC COVER DRAWING NUMBER
X.
X.0
: ±0.50
: ±0.25 0º 0' : ±00' 30''
THIS DRAWING IS OWNED BY CAPOTEX.
(THYSSENKRUPP ROBINS) THY_MAD_13 G
COPY OR REPRODUCTION IS FORBIDDEN
X.00 : ±0.08 WITHOUT PREVIOUS NOTICE (ANTAPACCAY PROJECT) CAD FILE
X.000 : ±0.02 0º 0' 0'' : ±00' 03''

(OVERLAND CONVEYOR CVB-0002) THY_MAD_13_G.dft
SELF-DRILLING SCREWS:
74mm 100mm
10mm
44mm
m
8m
76mm
O
LOOSE SCREW CORRECT TOO TIGHT
30mm
R
51mm
2"
22,5 mm 14mm
[ 7/8" ]
COVER
4" m
3/ 5 m
CAPOTEX SPECIAL
30mm
36 33,
1 1/8"
WASHER
9
R
LOCK / HINGE C-1
STEEL ANGLE 74x44x4 mm

[ 2 7/8" x 1 3/4" x 1/8" ]
L= 100 mm [ 3 7/8" ]
14,5mm
A
5/8"
SELF-DRILLING SCREWS
1822mm (SEE ATTACHED INFORMATION)
71 3/4"
BACK TO BACK CHANNELS DETAIL A

DATE 04-05-11 . .
NAME REV.
X.
X.0
: ±0.50
: ±0.25 0º 0' : ±00' 30''
X.000 : ±0.02 0º 0' 0'' : ±00' 03''

1292mm ±30 1292mm ±30 1292mm ±30 1292mm ±30
50 7/8" ±1,181 50 7/8" ±1,181 50 7/8" ±1,181 50 7/8" ±1,181
CORRUGATION DETAIL
76mm
18mm
3"
3/4"
Stiffening seal
Sheet thickness 0.6mm [Gauge 24]

and 1.2mm [Gauge 18] in edges.
1867mm 1400mm 1400mm 1400mm
18mm
73 1/2" 55 1/8" 55 1/8" 55 1/8"
3/4"
4200mm
165 3/8"
4" m
3/ 5m
36 33,
9
R
B
A
A 250 mm - [ 9 7/8" ] 140 mm - [ 5 1/2" ]

B 1183 mm - [ 46 5/8" ] 1093 mm - [ 43" ]
C 1880 mm - [ 74" ] 1822 mm - [ 71 3/4" ]
QTY 200 m. 360 m.
(*) Covers with holes in all peaks for plate mounting.
C
CS-3433
CS-3213

DATE 04-05-11 . .
NAME REV.
X.
X.0
: ±0.50
: ±0.25 0º 0' : ±00' 30''
X.000 : ±0.02 0º 0' 0'' : ±00' 03''

4mm
100mm
O
8m
15mm
m 70mm
65mm
105mm
R
84mm
3 1/4"
14mm
59,5mm
2 3/8" COVER
30mm
1 1/8"
CAPOTEX SPECIAL
4" m
3/ 5m
WASHER
36 33,
LOCK / HINGE C-1

9
R
STEEL PLATE 125x4 mm [ 4 7/8" x 1/8" ]

L= 100 mm [ 3 7/8" ]
SELF-DRILLING SCREWS
A (SEE ATTACHED INFORMATION)
"Z" PROFIL
(NOT SUPPLY BY CAPOTEX)
1822mm
71 3/4"
BACK TO BACK CHANNELS DETAIL A

DATE 04-05-11 . .
NAME REV.
X.
X.0
: ±0.50
: ±0.25 0º 0' : ±00' 30''
X.000 : ±0.02 0º 0' 0'' : ±00' 03''

4mm
100mm
O
15mm
14 70mm
m
m
65mm
105mm
R
84mm
3 1/4"
59,5mm
2 3/8"
14mm
COVER
CAPOTEX SPECIAL
30mm
4" m
1 1/8"
3/ 5m
WASHER
36 33,
9
LOCK / HINGE C-1

R
STEEL PLATE 105x4 mm [ 4 1/8" x 1/8" ]

18,5mm
L= 100 mm [ 3 7/8" ]
A
3/4"
BOLTS M12x45 [ ø1/2" x 1 3/4" ]

NUTS M12 [ ø1/2" ]
1880mm DETAIL A
74"
BACK TO BACK CHANNELS

DATE 04-05-11 . .
NAME REV.
X.
X.0
: ±0.50
: ±0.25 0º 0' : ±00' 30''
X.000 : ±0.02 0º 0' 0'' : ±00' 03''

4.3 IDLERS
LORBRAND, IDLERS
4.3.3 OPERATING INSTRUCTIONS 255

4.3.3.1 INSTALLATION 262
4.3.3.2 START-UP 264
4.3.3.3 MAINTENANCE AND INSPECTION 265
4.3.3.4 REPLACEMENT 266
4.3.3.5 STORAGE INSTRUCTIONS 267
Table of Contents 4.3 Idlers 4 Eqpt. Manuals
Idler Data Sheets_RC 23-08-2010

Job No.: 1002 Eng. Approval July 15, 2010
RFQ Number: 1002-004 Checked By: Rev C

Company Name LORBRAND (PTY) LTD
6 HENNOPSRIVER STREET, SUNDERLAND
Company Address
RIDGE, CENTURION, 0157, SOUTH AFRICA
Contact Person RALPH GRANIG
Fax Number +27 12 666 9187
e-mail Address diane@lorbrand.com
Proposal Reference Number LB96802 REV 3
Date of Proposal 23-Aug-10
TECHNICAL SPECIFICATION CVB-0001
Material Copper Ore
Capacity mtph 5263
Density (For Area / For Weight) kg/m^3 1600 / 1890
Surcharge Angle Deg 25
Belt Speed m/s 2.9
Drop Height m 5
Lump Size mm 400
Temperature °C -10 to 23
Carry Idler Vertical Misalignment mm 3.00
Return Idler Vertical Misalignment mm 3.00
Impact Idler Spacing m 0.3
Carry idler spacing m 1.2
Return Idler Spacing m 3.6
Est. Belt Weight kg/m 70.5
Max Carry Side Tension (Running) kN 205
Minimum Carry Side Tension (Running) kN 90
Max Return Side Tension (Running) kN 90
Minimum Return Side Tension (Running) kN 90
Dynamic Impact Factor for Impact Idlers (K1) 1.4
2.5-17.5 Degree Adjustable Transition Idlers (2-1/2 Increments)
Quantity 2
Model Number : Frame 72E6CF2.5-17.5
Model Number : Roller 72E6CR
Seal (Sealed for life) YES YES
Seal Type Triple Labyrinth / COMBINATION LABYRINTH CENTRIFUGAL
Taconite Service SELF CLEANING
Rolling Resistance N 8.6
Break-In Time hours 1
Idler Type Adj. Transition ADJ. TRANSITION
Idler Classification CEMA E E
No. Of Rolls In Each Set 3 3
Distance from Mounting Surface to Top of Cent. Roll mm 282 282
Roller Diameter mm 152 152
Shell Material Steel STEEL
Shell Thickness mm 6
Shell Thickness Tolerance mm 0.25 0.25
Rotating Mass kg 51.81
Required Idler Balancing ISO G 1940/1-1986 G40 ISO G 1940/1-1986 G40
Maximum TIR mm 0.71 0.5
Shaft Material Steel STEEL
Shaft Diameter mm 40
Shaft Deflection minutes 5.67
Bearing Size (Designation) 6308
1 of 14
12/5/2011


Bearing Type Deep Groove Ball (Anti- DEEP GROOVE BALL (ANTI-FRICTION)
Friction)
Bearing Life Hrs, L-10 60,000 >60,000
Bearing Manufacturer URB
Calculated Idler Load kN 7.94
Maximum Permissible Load on Frame kN 9.20
Maximum Permissible Load on Rollers kN 12.60
Total Idler Set Weight kg 127
Paint - Idler Rolls ETCH PRIMER
Paint - Idler Frames 2 COAT EPOXY
Non-Flammable Grease NO NO
Wide Base Req'd YES YES
Quantity 3
Idler Type Adj. Transition ADJ. TRANSITION
Friction)
55 Degree Impact Idlers w/ Rubber Disc - Garland / Catenary
Quantity 11
Model Number : Frame N/A
Model Number : Roller 72E8.5IR5
2 of 14
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Idler Type 55° Impact 55º IMPACT
Idler Life hours 25,000 25000
Distance from Mounting Surface to Top of Cent. Roll mm TBA TBA
Shell Material Steel/Rubber STEEL/RUBBER
Friction)
Maximum Permissible Load on Frame kN N/A
Total Idler Set Weight kg 102.4
45 Degree Troughing Idler - Retractable Frame
Quantity 35
Model Number : Frame 72E6CF-R
Idler Type 45° Trough 45° Trough
Bearing Type Deep Groove Ball (Anti- Deep Groove Ball (Anti-Friction)
Friction)
3 of 14
12/5/2011


35 Degree Troughing Idler - Standard Frame
Quantity 56
Model Number : Frame 72E6CF
Friction)
35 Degree Troughing Idler - Belt Scale Quality w/ Belt Scale Frame
Quantity 4
Model Number : Frame 72E7SF-0B
Model Number : Roller 72E7SR
4 of 14
12/5/2011


Friction)
Bearing Life Hrs, L-10 60,000 209,000
35 Degree Troughing Idler - Belt Scale Quality w/ Standard Frame
Quantity 8
Model Number : Frame 72E6SF-S
Model Number : Roller 72E6SR
Friction)
5 of 14
12/5/2011


35 Degree Troughing Idler - w/ Trough Banked at 5 Degrees (For Horizontal Curve)
Quantity 0
Model Number : Frame
Model Number : Roller
Seal (Sealed for life) YES
Seal Type Triple Labyrinth /
Taconite Service
Rolling Resistance N
Break-In Time hours
Idler Type 35° Trough
Idler Classification CEMA E
No. Of Rolls In Each Set 3
Distance from Mounting Surface to Top of Cent. Roll mm 310
Roller Diameter mm 178
Shell Material Steel
Shell Thickness mm
Shell Thickness Tolerance mm 0.25
Rotating Mass kg
Required Idler Balancing ISO G 1940/1-1986 G40
Maximum TIR mm 0.5
Shaft Material Steel
Shaft Diameter mm
Shaft Deflection minutes
Bearing Size (Designation)
Bearing Type Deep Groove Ball (Anti-
Friction)
Bearing Life Hrs, L-10 60,000
Bearing Manufacturer
Calculated Idler Load kN
Maximum Permissible Load on Frame kN
Maximum Permissible Load on Rollers kN
Total Idler Set Weight kg
Paint - Idler Rolls
Paint - Idler Frames
Non-Flammable Grease NO
Wide Base Req'd YES
35 Degree Troughing Idler - Low Profile
Quantity 0
Taconite Service
Break-In Time hours
6 of 14
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Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
15 Degree V-Return Idler
Quantity 20
Model Number : Frame 72E7.5VF
Model Number : Roller 72E7.5R
Idler Type 15° Vee 15° Vee
Distance from Mounting Surface to V Point mm 341 341
Shaft Deflection minutes 2
Friction)
7 of 14
12/5/2011


15 Degree V-Return Idler - Vee banked at 5 Degrees (For Horizontal Curve)
Quantity 0
Taconite Service
Break-In Time hours
Idler Type 15° Vee
Idler Classification CEMA
Distance from Mounting Surface to V Point mm 325
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
Flat Return Idlers (2-Roll)
Quantity 2
Taconite Service
Break-In Time hours
Idler Type Flat Return
Distance from Mounting Surface to Top Rolls mm 341
Shell Thickness mm
Rotating Mass kg
8 of 14
12/5/2011


Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
15 Degree V-Return Idler (Low Drop)
Quantity 0
Taconite Service
Break-In Time hours
Idler Type 15° Vee
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
Flat Return Idlers (2-Roll, Low Drop)
Quantity 1
9 of 14
12/5/2011


Taconite Service
Break-In Time hours
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
15 Degree V-Return Idlers w/ Rubber Discs (hanging frame, rollers offset from cross member)
Quantity 8
Taconite Service
Break-In Time hours
Idler Type 15° Vee
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
10 of 14
12/5/2011


Friction)
Paint - Idler Rolls
Wide Base Req'd YES
Flat Return Idlers w/ Rubber Discs (2-Roll, hanging frame, rollers offset from cross member)
Quantity 2
Taconite Service
Break-In Time hours
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
15 Degree V-Return Idlers w/ Steel Rolls (under slung frame, rollers inline with cross member)
Quantity 0
Taconite Service
11 of 14
12/5/2011


Break-In Time hours
Idler Type 15° Vee
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
Flat Return Idlers w/ Steel Rolls (2-Roll, under slung frame, rollers inline with cross member)
Quantity 0
Taconite Service
Break-In Time hours
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
12 of 14
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Paint - Idler Rolls
Wide Base Req'd YES
Inverted V-Return Training Idler w/ Carry Rolls
Quantity 1
Taconite Service
Break-In Time hours
Idler Type Inverted Vee
Distance from Mounting Surface to V Point mm TBA
Shell Material Steel/Rubber
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
Live Shaft Idlers
Quantity 2
Taconite Service
Break-In Time hours
Idler Type Live Shaft
13 of 14
12/5/2011


Distance from Mounting Surface to V Point mm TBA
Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.5
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
14 of 14
12/5/2011


6 HENNOPSRIVER STREET, SUNDERLAND
Company Address
RIDGE, CENTURION, 0157, SOUTH AFRICA
Contact Person RALPH GRANIG
Fax Number +27 12 666 9187
e-mail Address diane@lorbrand.com
Proposal Reference Number LB96802 REV 3
Date of Proposal 23-Aug-10
TECHNICAL SPECIFICATION CVB-0002
Material Copper Ore
Capacity mtph 5263
Density (For Area / For Weight) kg/m^3 1600 / 1890
Surcharge Angle Deg 25
Belt Speed m/s 6.2
Drop Height m 5
Lump Size mm 400
Temperature °C -10 to 23
Carry Idler Misalignment mm 3.00
Return Idler Misalignment mm 3.00
Impact Idler Spacing m 0.3
Carry idler spacing m 1.4
Return Idler Spacing m 4.2
Est. Belt Weight kg/m 85.5
Max Carry Side Tension (Running) kN 1275
Minimum Carry Side Tension (Running) kN 170
Max Return Side Tension (Running) kN 1295
Minimum Return Side Tension (Running) kN 100
Dynamic Impact Factor for Impact Idlers (K1) 1.4
Quantity 8
Idler Type Adj. Transition Adj. Transition
1 of 14
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Friction)
Quantity 7
Idler Type Adj. Transition Adj. Transition
Friction)
55 Degree Impact Idlers w/ Rubber Disc - Garland / Catenary
Quantity 7
Model Number : Frame N/A
Model Number : Roller 54E7IR5
2 of 14
12/5/2011


Idler Type 55° Impact 55° Impact
Idler Life hours 25,000 25000
Distance from Mounting Surface to Top of Cent. Roll mm TBA TBA
Shell Material Steel/Rubber Steel/Rubber
Friction)
Bearing Life Hrs, L-10 60,000 1.1X10E6
Maximum Permissible Load on Frame kN N/A
45 Degree Troughing Idler - Retractable Frame
Quantity 19
Model Number : Frame 54E7CFR
Friction)
Bearing Life Hrs, L-10 60,000 123000
3 of 14
12/5/2011


35 Degree Troughing Idler - Standard Frame
Quantity 3140
Model Number : Frame 54E7CF
Friction)
Bearing Life Hrs, L-10 60,000 123000
35 Degree Troughing Idler - Belt Scale Quality w/ Belt Scale Frame
Quantity 0
Taconite Service
Break-In Time hours
4 of 14
12/5/2011


Shell Thickness mm
Rotating Mass kg
Maximum TIR mm 0.25
Shaft Diameter mm
Friction)
Paint - Idler Rolls
Wide Base Req'd YES
35 Degree Troughing Idler - Belt Scale Quality w/ Standard Frame
Quantity 0
Taconite Service
Break-In Time hours
Idler Type

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Faja Overland o&m Manual 620mr002-Preliminary

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620MR00

1.1 TKRI SAFETY CREED 5

2.1 CONVEYOR DATA SHEET 96

3.1 OPERATING & MAINTENANCE MANUAL 150

4.1 METAL DETECTOR SERIES 9000A, ADVANCED DETECTION SYSTEMS 189

1.1 TKRI SAFETY CREED 5

ThyssenKrupp Safety Creed

ThyssenKrupp Safety Creed

ThyssenKrupp Safety Creed

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

SAFETY STANDARD FOR

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

2 REFERENCE TO OTHER CODES

Proposals should be written in accordance with the following format:

(a) Specify page and paragraph designation of the pertinent Standard.

The request for interpretation shall be in the following format:

Question: Phrase the question as a request for an interpretation of a specific requirement

ASME procedures provide for reconsideration of any interpretation when or if additional

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

automatically controlled: describes the operation be the action of a mechanism that is

backstop: a mechanical device to prevent reversal of a loaded conveyor under action of

boom: a cantilevered member or structure that may be hinged, fixed, or pivoted.

bunker: a large bin or compartment for storage of bulk materials.

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

controller: an electromechanical device or assembly of devices for starting, stopping,

conveyor, declining: a conveyor transporting down a slope.

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

conveyor, en masse: a conveyor, comprised of a series of skeleton or solid flights on an

conveyor, extendable: a conveyor that may be lengthened or shortened to suit operating

conveyor, horizontal reciprocating: a conveyor that progressively advances material by a

conveyor, portable: a transportable conveyor that is not self-propelled, usually having

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

conveyor, roller slat: a slat conveyor using rollers for slats.

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

(b): a structure mounted below an overhead mounted conveyor to protect

guarded: shielded, fenced, enclosed, or otherwise protected by means of suitable enclosure,

hopper: a box having a funnel-shaped bottom, or a bottom reduced in size, narrowed, or

overload device: a mechanical or electrical device designed to disconnect the driven

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

qualified person: a person who, by possession of a recognized degree or certificate of

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

should: as used in the context of a provision of this Standard, indicates a recommendation,

stacker. a conveyor adapted to piling or stacking bulk materials, packages, or objects.

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

truck (also known as cart)

5 GENERAL SAFETY STANDARDS3

Conveyor equipment shall be used to convey only the specified commodities or

5.2 Maintenance (Repair)

(a) Maintenance and service shall be performed by qualified and trained

(c) No maintenance or service shall be performed when a conveyor is in

ASME B20.1-2003 SAFETY STANDARD FOR CONVEYORS AND RELATED EQUIPMENT

(a) Conveyors shall not be lubricated while in operation unless it is impractical to

5.4 Adjustment or Maintenance During Operation

When adjustment or maintenance must be done while equipment is in operation, only

5.5 Backstops and Breaks

Anti-runaway, brake, or backstop devices shall be provided on all incline, decline, or